APRILIA ATLANTIC 500 Technical data

1073 1
ATLANTIC 500
10/2002-00
8140632
workshopmanual
LIST OF SECTIONS
Foreword
This manual provides basic information about ordinary
vehicle servicing procedures.
The data and illustrations that make up the manual
were up to date at the time of publication.
The manual is intended for aprilia dealers and their
qualified mechanics. Many concepts have been intentionally omitted as they were considered superfluous.
Since this publication cannot provide exhaustive
mechanical knowledge, it is assumed that people who
make use of this manual have received a basic
training in mechanics and possess a working knowledge of vehicle repairing techniques.
Repairing or checking the vehicle without such knowledge would be ineffective and even dangerous.
As the repairing and checking procedures are not
described in full detail, special care should be taken to
avoid damage to property and personal injury.
With a view to providing its customers with the best
possible riding experience, aprilia is committed to
continually improving its products and the accompanying documentation.
aprilia dealers and world branches are informed about
all major technical modifications and changes in
repairing procedures. Such modifications will be
covered in later editions of this manual.
Should any need or doubt arise about repairing and
checking procedures, do not hesitate to contact aprilia’s
Consumer Service (A.C.S.): they will be pleased to
provide any information you may require and let you
know of any technical modifications and updates.
For further information, please refer to:
SPARE PARTS CATALOGUE 6801;
ROTAX ENGINE WORKSHOP MANUAL 10631-I
10641-E
10651-F
10661-D
10671-UK
10681-USA
The main features described herein remaining unchanged, aprilia reserves the right to change its
models at any time.
The right to store this document in electronic form and
to adapt or reproduce it in whole or in part is reserved
worldwide.
The mention of third parties’ products and services is
made for the sole purpose of information and constitutes no engagement.
aprilia assumes no responsibility about the performance and use of such products or services.
First edition: september 2002
Produced and printed by:
CLD s.r.l. Editing division
Via D. Alighieri, 37/A - 56012 Fornacette (PI)
Tel. +39 (0)587 - 42 28 00
Fax +39 (0)587 - 42 28 01
www.cld.it
E-mail: cld@cld.it
On behalf of:
aprilia S.p.A.
Via G. Galilei, 1 - 30033 Noale (VE) - Italia
Tel.
+39 (0)41 - 58 29 111
Fax
+39 (0)41 - 44 10 54
www.aprilia.com
www.serviceaprilia.com
General Information
Periodic Maintenance
Operations
Engine
Fuel System
Cooling System
Electrical Equipment
Cycle Parts
1
2
3
4
5
6
7
Atlantic 500
TABLE OF CONTENTS
Chapter 1
SAFETY WARNINGS ............................................................................................................................. 1-2
PRECAUTIONS AND GENERAL INFORMATION ................................................................................. 1-2
REPLACING COMPONENTS ................................................................................................................ 1-3
USING THE MANUAL ............................................................................................................................ 1-3
IDENTIFICATION DATA ......................................................................................................................... 1-4
NOTES ON FUEL, LUBRICANTS, COOLANT AND OTHER ITEMS .................................................... 1-4
FUEL ...................................................................................................................................................... 1-4
RUNNING-IN RULES ............................................................................................................................. 1-8
PRECAUTIONS AND GENERAL INFORMATION ................................................................................. 1-9
SPARE PARTS ....................................................................................................................................... 1-9
TECHNICAL DATA ............................................................................................................................... 1-10
LUBRICANT CHART............................................................................................................................ 1-12
TIGHTENING TORQUES TABLE ........................................................................................................ 1-13
Chapter 2
PERIODIC MAINTENANCE PROGRAMME .......................................................................................... 2-2
PERIODIC MAINTENANCE SCHEDULE .............................................................................................. 2-3
LUBRICATING POINTS ......................................................................................................................... 2-4
BATTERY ............................................................................................................................................... 2-5
REMOVING THE BATTERY COVER .................................................................................................... 2-6
CHECKING AND CLEANING THE TERMINALS ................................................................................... 2-6
REMOVING THE BATTERY .................................................................................................................. 2-7
LONG INACTIVATY OF THE BATTERY ................................................................................................ 2-7
CHECKING THE ELECTROLYTE LEVEL ............................................................................................. 2-8
RECHARCING THE BATTERY .............................................................................................................. 2-8
INSTALLING THE BATTERY ................................................................................................................. 2-9
SPARK PLUG ........................................................................................................................................ 2-9
ADJUSTING THE THROTTLE CONTROL .......................................................................................... 2-10
AIR FILTER .......................................................................................................................................... 2-11
ENGINE OIL ......................................................................................................................................... 2-12
CHECKING AND RESTORING THE ENGINE OIL LEVEL .................................................................. 2-12
RENEWING THE ENGINE OIL AND ................................................................................................... 2-13
THE ENGINE OIL FILTER ................................................................................................................... 2-13
CHECKING THE TRANSMISSION OIL LEVEL AND TOPPING UP.................................................... 2-14
TOPPING UP ....................................................................................................................................... 2-15
RENEWING THE TRANSMISSION OIL .............................................................................................. 2-16
DISC BRAKES ..................................................................................................................................... 2-16
CHECK ................................................................................................................................................. 2-17
RESTORING THE BRAKE FLUID LEVEL ........................................................................................... 2-18
CHECKING BRAKE PAD WEAR ......................................................................................................... 2-18
BLEEDING THE BRAKING SYSTEM (FRONT SIDE ONLY) .............................................................. 2-19
BLEEDING THE INTEGRAL BRAKING SYSTEM ............................................................................... 2-20
CHECKING AND RESTORING THE COOLANT LEVEL .................................................................... 2-22
RENEWING THE COOLANT ............................................................................................................... 2-23
CIRCUIT BLEEDING ........................................................................................................................... 2-25
CHECKING AND ADJUSTING THE STEERING ................................................................................. 2-25
ADJUSTING THE BEARINGS PLAY ................................................................................................... 2-26
STEERING DAMPER .......................................................................................................................... 2-26
CHECK ENGINE PIN BUSHINGS ....................................................................................................... 2-26
CHECKING THE FRONT SUSPENSION ............................................................................................ 2-27
CHECKING THE REAR SUSPENSION .............................................................................................. 2-27
ADJUSTING THE REAR SUSPENSION ............................................................................................. 2-27
ADJUSTMENT OF THE REAR SUSPENSION SPRING PRELOAD .................................................. 2-28
WHEELS AND TYRES ......................................................................................................................... 2-28
WHEELS INSPECTION ....................................................................................................................... 2-28
TYRES ................................................................................................................................................. 2-28
PRESSURE TYRES ............................................................................................................................ 2-30
2
Release 00
2002-09
Atlantic 500
Chapter 3
COMPONENTS THAT CAN BE REMOVED WITHOUT REMOVING THE ENGINE............................. 3-2
REMOVING THE ENGINE FROM THE FRAME ................................................................................... 3-3
Chapter 4
FUEL TANK AND PUMP ........................................................................................................................ 4-2
EMS FUEL INJECTION SYSTEM.......................................................................................................... 4-2
FUEL SUPPLY SYSTEM ....................................................................................................................... 4-3
FUEL SUPPLY CHECK .......................................................................................................................... 4-4
FUEL PUMP REMOVAL/DISMANTLING ............................................................................................... 4-5
FUEL PUMP AND FUEL LEVEL FEELER DISASSEMBLY AND CHECKING ....................................... 4-6
THROTTLE BODY ................................................................................................................................. 4-6
THROTTLE BODY REMOVAL ............................................................................................................... 4-7
Chapter 5
SYSTEM DESCRIPTION ....................................................................................................................... 5-2
COOLANT .............................................................................................................................................. 5-2
RADIATOR REMOVAL ........................................................................................................................... 5-3
ELECTRICAL COOLING FAN REMOVAL ............................................................................................. 5-3
EXPANSION TANK REMOVAL .............................................................................................................. 5-4
THERMOSTAT VALVE ........................................................................................................................... 5-5
COOLANT PUMP .................................................................................................................................. 5-5
COOLANT THERMISTOR ..................................................................................................................... 5-5
Chapter 6
CHECKING THE RECHARGING SYSTEM ........................................................................................... 6-2
CHECKING THE RECHARGING VOLTAGE ......................................................................................... 6-2
CHECKING THE ALTERNATOR NO-LOAD .......................................................................................... 6-2
CHECKING THE ALTERNATOR CONTINUITY ..................................................................................... 6-3
VOLTAGE REGULATOR ........................................................................................................................ 6-3
FUEL INJECTION SYSTEM .................................................................................................................. 6-4
INJECTION SUPPLY WIRE DIAGRAM ................................................................................................. 6-4
STAND SWITCH CONTROL ................................................................................................................. 6-5
INJECTION RELAY CONTROLS ........................................................................................................... 6-5
IGNITION/INJECTION SYSTEM ........................................................................................................... 6-7
E.C.U. CONNECTIONS ......................................................................................................................... 6-7
CONNECTIONS TO THE E.C.U. CONTROL UNIT ............................................................................... 6-9
CHECKING THE HV COIL ................................................................................................................... 6-10
DROP SENSOR CHECK ..................................................................................................................... 6-11
RPM SENSOR CHECK ....................................................................................................................... 6-12
THROTTLE VALVE POTENTIOMETER (ACCELERATOR SENSOR) CHECK .................................. 6-13
INJECTOR CHECK .............................................................................................................................. 6-14
COOLANT THERMISTOR FUNCTION CHECK .................................................................................. 6-14
FUEL PUMP CHECK ........................................................................................................................... 6-15
AIR THERMISTOR FUNCTION CHECK ............................................................................................. 6-15
STARTING AND STOP LIGHTS SYSTEM .......................................................................................... 6-16
STARTING RELAY CHECK ................................................................................................................. 6-17
STOP LIGHTS RELAY CHECK ........................................................................................................... 6-17
ELECTRIC COOLING FAN .................................................................................................................. 6-19
CHECKING THE ELECTRIC FAN ....................................................................................................... 6-19
WATER THERMISTOR CHECK .......................................................................................................... 6-20
FAN RELAY CHECK ............................................................................................................................ 6-20
COOLANT TEMPERATURE AND FUEL LEVEL INDICATORS ........................................................... 6-21
WIRING DIAGRAM .............................................................................................................................. 6-21
WATER TEMPERATURE ..................................................................................................................... 6-22
Release 00
2002-09
3
Atlantic 500
DASHBOARD CHECK ......................................................................................................................... 6-22
FUEL LEVEL ........................................................................................................................................ 6-22
DASHBOARD CHECK ......................................................................................................................... 6-22
FUEL LEVEL SENSOR CHECK .......................................................................................................... 6-22
LIGHTS AND ACOUSTIC SIGNALS SYSTEM .................................................................................... 6-23
WIRING DIAGRAM .............................................................................................................................. 6-23
HORN CHECK ..................................................................................................................................... 6-23
TOP CASE SWITCH CHECK .............................................................................................................. 6-23
DIRECTION INDICATORS AND DISPLAY DATA ................................................................................ 6-24
WIRING DIAGRAM .............................................................................................................................. 6-24
CONTROLS ON THE LEFT SIDE OF THE HANDLEBAR .................................................................. 6-24
DIRECTION INDICATOR AND SPEEDOMETER ................................................................................ 6-27
WIRING DIAGRAM .............................................................................................................................. 6-27
DASHBOARD CHECK ......................................................................................................................... 6-28
SENSOR CHECK ................................................................................................................................ 6-28
SPEEDOMETER .................................................................................................................................. 6-29
AIR TEMPERATURE SENSOR ........................................................................................................... 6-30
SWITCHES .......................................................................................................................................... 6-31
BULB REPLACEMENT ........................................................................................................................ 6-32
BATTERY ............................................................................................................................................. 6-33
NUMBER PLATE LIGHT REPLACEMENT .......................................................................................... 6-36
HELMET COMPARTMENT LIGHT REPLACEMENT .......................................................................... 6-36
THIRD STOP LIGHTS REPLACEMENT.............................................................................................. 6-36
VERTICAL BEAM ADJUSTMENT ........................................................................................................ 6-37
HORIZONTAL BEAM ADJUSTMENT .................................................................................................. 6-38
REPLACING THE FUSES ................................................................................................................... 6-38
ELECTRICAL COMPONENTS LAYOUT ............................................................................................. 6-40
ELECTRICAL COMPONENTS LAYOUT ............................................................................................. 6-41
WIRING DIAGRAM 500 C.C. ATLANTIC SCOOTER .......................................................................... 6-42
Chapter 7
BODYWORK .......................................................................................................................................... 7-2
PASSENGER FOOTREST REMOVAL .................................................................................................. 7-2
LOWER PROTECTION COVER REMOVAL ......................................................................................... 7-2
UNLOCKING/LOCKING THE SEAT ...................................................................................................... 7-2
SEAT REMOVAL .................................................................................................................................... 7-3
CENTRAL TUNNEL REMOVAL ............................................................................................................. 7-3
LEFT AND RIGHT HAND INSPECTION COVER REMOVAL ................................................................ 7-4
LEGSHIELD REMOVAL ......................................................................................................................... 7-4
DOCUMENT COMPARTMENT .............................................................................................................. 7-6
FRONT MUDGUARD REMOVAL .......................................................................................................... 7-6
PASSENGER HANDLE-GRIP REMOVAL ............................................................................................. 7-7
COMPLETE SIDE PANEL REMOVAL ................................................................................................... 7-7
REMOVAL OF THE CHROMED STRIP FROM THE SIDE PANELS ..................................................... 7-8
SIDE PANEL SEPARATION ................................................................................................................... 7-8
FOOT PLATFORM REMOVAL ............................................................................................................... 7-9
SPRAY GUARD REMOVAL ................................................................................................................... 7-9
FRONT SHIELD REMOVAL................................................................................................................. 7-10
PASSENGER BACKREST REMOVAL ................................................................................................ 7-10
PLASTIC BACKREST REMOVAL........................................................................................................ 7-10
REAR MUDGUARD REMOVAL ........................................................................................................... 7-11
LOWER COVER REMOVAL ................................................................................................................ 7-12
TAIL UNIT REMOVAL .......................................................................................................................... 7-12
FOOTREST SUPPORT AND LOWER SPRAY GUARD REMOVAL .................................................... 7-13
FRONT PANEL REMOVAL .................................................................................................................. 7-14
UPPER HANDLEBAR COVER REMOVAL .......................................................................................... 7-14
LOWER HANDLEBAR COVER REMOVAL ......................................................................................... 7-15
4
Release 00
2002-09
Atlantic 500
COMPLETE INSTRUMENT PANEL REMOVAL .................................................................................. 7-15
WINDSHIELD REMOVAL .................................................................................................................... 7-16
INSTRUMENT PANEL REMOVAL ....................................................................................................... 7-16
COMPLETE LIGHTING ASSEMBLY REMOVAL ................................................................................. 7-17
CRASH HELMET COMPARTMENT REMOVAL .................................................................................. 7-18
FRONT WHEEL ................................................................................................................................... 7-22
KEY ...................................................................................................................................................... 7-22
REMOVING THE FRONT WHEEL ...................................................................................................... 7-23
REPLACING THE BEARINGS ............................................................................................................. 7-24
CHECK ................................................................................................................................................. 7-25
REFITTING THE FRONT WHEEL ....................................................................................................... 7-26
REAR WHEEL ..................................................................................................................................... 7-27
KEY ...................................................................................................................................................... 7-27
REMOVING THE REAR WHEEL ......................................................................................................... 7-28
REMOVING THE EXHAUST TERMINAL ............................................................................................ 7-29
CHECK ................................................................................................................................................. 7-30
FRONT BRAKE .................................................................................................................................... 7-30
KEY ...................................................................................................................................................... 7-31
REPLACING THE BRAKE PADS......................................................................................................... 7-32
CHECKING THE BRAKE DISC ........................................................................................................... 7-33
REMOVING THE BRAKE DISC ........................................................................................................... 7-33
REAR BRAKE ...................................................................................................................................... 7-33
KEY ...................................................................................................................................................... 7-34
REPLACING THE BRAKE PADS......................................................................................................... 7-35
CHECKING THE BRAKE DISC ........................................................................................................... 7-36
REMOVING THE BRAKE DISC ........................................................................................................... 7-36
STEERING ........................................................................................................................................... 7-37
CHECKING THE BEARINGS .............................................................................................................. 7-39
KEY ...................................................................................................................................................... 7-40
CHECKING THE OIL LEVEL ............................................................................................................... 7-41
REMOVING THE FORK ASSEMBLY................................................................................................... 7-41
REMOVING THE ROD-WHEEL CARRIER ASSEMBLY ..................................................................... 7-42
WHEEL CARRIER ROD DISASSEMBLY ............................................................................................ 7-43
CHECKING THE COMPONENTS ....................................................................................................... 7-44
ADJUSTING THE REAR SUSPENSION ............................................................................................. 7-44
ADJUSTMENT OF THE REAR SUSPENSION SPRING PRELOAD .................................................. 7-45
REMOVING THE SHOCK ABSORBER ............................................................................................... 7-45
Release 00
2002-09
5
Atlantic 500
6
Release 00
2002-09
General Information
Atlantic 500
1
General Information
chap. 1
Release 00
2002-09
1-1
General Information
Atlantic 500
SAFETY WARNINGS
The following precautionary warnings are used throughout this manual in order to convey the following messages:
Safety warning. When you find this symbol on the vehicle or in the manual, be careful to the potential
risk of personal injury. Non-compliance wit the indications given in the message preceded by this
symbol may result in grave risks for your and other people’safety and for the vehicle!
WARNING
Indicates a potential hazard which may result in serious injury or even death.
CAUTION
Indicates a potential hazard which may result in minor personal injury or damage to the vehicle.
NOTE The word “NOTE” in this manual precedes important information or instructions.
PRECAUTIONS AND GENERAL INFORMATION
When repairing, disassembling and reassembling the vehicle, scrupulously observe the following recommendations.
WARNING
The use of open flames is forbidden under all circumstances.
Before performing any servicing or checks, switch off the engine, remove the ignition key, allow the engine
and the exhaust system to cool down, and if possible lift the vehicle on solid level flooring using specific
equipment.
To avoid burns, pay special attention to hot engine and exhaust parts.
The vehicle is made up of inedible parts. On no account must any parts be bitten, sucked, chewed or
swallowed.
Unless otherwise specified, the reassembly of parts is carried out by following the disassembling procedures in reverse order.
Any overlapping operations in cross-references to other chapters should be interpreted logically so as to
avoid unnecessary removal of components.
Never use fuel as a solvent to clean the vehicle.
Disconnect the battery negative (-) cable, control unit and spark plug lug, before performing any electric
welding.
When two or more people are working at the same time, pay attention to the safety of each of them.
BEFORE REMOVING COMPONENTS
Remove any dirt, mud, dust and foreign bodies from the vehicle before removing any components.
Use the tools specially designed for this vehicle whenever necessary.
REMOVING COMPONENTS
Never loosen screws and nuts using tools other than the specific spanners.
Mark the positions on all connecting joints (pipes, cables, etc.) before separating them, and identify them with
different marks.
Clearly mark each part so it can be easily identified during reinstallation.
Clean and wash the removed components with a low-flash detergent.
Keep mating parts together, as they have adapted to one another through wear and tear. Some components must
be used in combination or replaced as a set.
Keep away from heat sources.
1-2
Release 00
2002-09
chap. 1
General Information
Atlantic 500
REPLACING COMPONENTS
CAUTION
1
Never reuse circlips. Always replace removed circlips with new ones.
When fitting a new circlip, take care not to part its ends more than is required to fit it on the shaft.
After fitting a circlip, ensure that it is fully and firmly inserted in its seat.
Never use compressed air to clean the bearings.
NOTE Bearings should always rotate freely, smoothly and silently, otherwise they must be replaced.
Only use GENUINE aprilia spares.
Always use the recommended lubricants and consumables.
If possible, lubricate parts before refitting them.
When tightening screws and nuts, start with the larger or the inner ones, and then proceed diagonally.
Carry out the tightening in successive steps before applying the full tightening torque.
Always replace self-locking nuts, seal rings, circlips, O-rings, cotter pins and screws (if the threads are damaged)
with new ones.
Clean all mating surfaces, oil seal rims and gaskets before refitting.
Apply a film of lithium grease to the oil seal rims.
Replace the oil seals and the bearings so that the marks or serial numbers face outwards (side in view).
Generously lubricate the bearings before fitting them.
Check that every component has been fitted properly.
After repairing or servicing any parts, carry out preliminary checks and test the vehicle on private ground or in a
low-traffic area.
USING THE MANUAL
HOW TO CONSULT THE MANUAL
The manual is divided into chapters, each corresponding to a major type of components.
For easy reference, refer to the TABLE OF CONTENTS.
Unless otherwise specified, parts are reassembled by following the disassembling procedures in reverse order.
The terms “left” and “right” refer to the rider sitting on the vehicle in a normal riding position.
Refer to the “OPERATION AND MAINTENANCE MANUAL” for information on how to operate and maintain the
vehicle.
chap. 1
Release 00
2002-09
1-3
General Information
Atlantic 500
IDENTIFICATION DATA
The frame number may be used to order the spare
parts.
NOTE Tampering with serial numbers is subject to
1
severe penalties. In particular, tampering with the
frame number immediately voids the warranty.
FRAME NUMBER
The frame number is stamped on the frame central
tube. To read it, open the central glove compartment
door and remove the cover (1).
ENGINE NUMBER
The engine number is stamped near the lower support
of the rear shock absorber.
NOTES ON FUEL, LUBRICANTS, COOLANT AND OTHER ITEMS
FUEL
WARNING
The fuel used in internal combustion engines is highly flammable and can be explosive under certain
conditions.
Refuelling and servicing should be carried out in a well ventilated place after switching off the engine.
Do not smoke while refuelling or in the presence of fuel fumes. Avoid contact with open flames, sparks and
any other potential source of ignition or explosion.
Avoid spilling fuel from the tank filler as it may catch fire on contact with the hot engine surfaces.
Should any fuel be inadvertently spilled, be sure to dry up the area before starting the engine.
Since fuel expands when exposed to heat and direct sunlight, avoid filling the tank to the brim.
Carefully close the tank cap after refuelling.
Do not allow fuel to come into contact with the skin and avoid ingesting it or inhaling its fumes. Do not
transfer fuel from one vessel into another using a length of tube.
DO NOT DISPOSE OF FUEL IN THE ENVIRONMENT.
KEEP OUT OF REACH OF CHILDREN.
Use only leaded (4 Stars ) or unleaded premium grade petrol, min. O. N. 95 (N. O. R. M.) and 85 (N. O. M. M.).
1-4
Release 00
2002-09
chap. 1
General Information
Atlantic 500
ENGINE OIL
WARNING
1
Engine oil can cause serious damage to the skin if handled every day and for long periods.
Wash your hands carefully after using the oil.
Do not dispose of the oil in the environment.
Put it in a sealed container and take it to the filling station where you usually buy it or to an oil salvage
center.
In case any maintenance operation has to be carried out, it is advisable to use latex gloves.
Check the engine oil after the first 1,000 km (625 mi) and then every 3,000 km (1,875 mi). Change the oil every
6,000 km (3,750 mi), see CHANGING THE ENGINE OIL AND THE ENGINE OIL FILTER.
Engine oil (recommended):
Synthetic oil SAE 5W/40 of the SELENIA HI Scooter 4Tech type. Alternatively, use brand-name oils with performance complying with or exceeding the A.P.I. SJ specifications.
TRANSMISSION OIL
WARNING
Transmission oil can cause serious damage to the skin if handled every day and for long periods.
Wash your hands carefully after using the oil.
Do not dispose of the oil in the environment.
Put it in a sealed container and take it to the filling station where you usually buy it or to an oil salvage
center.
In case any maintenance operation has to be carried out, it is advisable to use latex gloves.
Renew the transmission oil after the first 1,000 km (625 mi) and then every 12,000 km (7,500 mi). Refer to
the engine workshop manual.
Transmission oil (recommended):
SAE 80W/90 oil of the TUTELA ZC90 type.
Alternatively, use brand-name oils with performance complying with or exceeding the A.P.I. GL-3 specifications.
BRAKE FLUID
WARNING
Brake fluid can cause irritation if it comes into contact with the skin or the eyes.
Carefully wash any parts of the body that should happen to come into contact with the fluid. Contact an
ophthalmologist or a physician if the fluid comes into contact with the eyes.
DO NOT DISPOSE OF THE FLUID IN THE ENVIRONMENT.
KEEP OUT OF REACH OF CHILDREN.
When handling brake fluid, take care not to spill it on plastic and painted parts as they would be damaged.
Check the brake fluid level every 6,000 km (3,750 mi) (CHECKING AND RESTORING THE FRONT BRAKE
FLUID LEVEL). Renew the fluid every 2 years (RENEWING THE FRONT BRAKE FLUID).
Brake fluid (recommended):
TUTELA TOP 4.
Alternatively, use brand-name brake fluids with performance complying with or exceeding the specifications.
Synthetic fluid SAE J1703, NHTSA 116 DOT 4, ISO 4925
chap. 1
Release 00
2002-09
1-5
General Information
Atlantic 500
CAUTION
Do not use brake fluids other than those prescribed. To avoid damaging the braking system, never mix
different types of fluids when topping up.
Never use brake fluid taken from an old container, or from a container that has been open for a long time.
Sudden changes in brake play or a spongy feel of the brake levers are due to problems in the hydraulic
circuits.
Take special care in ensuring that the brake discs and the brake linings are not oily or greasy, especially
after checking or servicing the brakes.
Ensure that the brake lines are not twisted or worn.
Take care not to let any water or dust into the brake circuit.
Latex gloves are recommended for all maintenance operations involving the hydraulic circuit.
FORK OIL
WARNING
Fork oil can cause serious damage to the skin if handled every day and for long periods.
Wash your hands carefully after using the oil.
Do not dispose of the oil in the environment.
Put it in a sealed container and take it to the filling station where you usually buy it or to an oil salvage
center.
In case any maintenance operation has to be carried out, it is advisable to use latex gloves.
The response of the suspension can be partly altered by changing the adjustment of the shock absorbers
and/or the viscosity of the oil they contain.
Viscosity grades can be chosen according to the desired vehicle geometry.
1-6
Release 00
2002-09
chap. 1
General Information
Atlantic 500
COOLANT
WARNING
The coolant is harmful if ingested. Contact with the skin or the eyes may cause irritation. Should the liquid
come into contact with the skin or the eyes, generously rinse with water and seek medical attention.
If the fluid is ingested, cause vomiting, generously rinse the mouth and throat with water and immediately
seek medical attention.
DO NOT DISPOSE OF THE COOLANT IN THE ENVIRONMENT.
KEEP OUT OF REACH OF CHILDREN.
WARNING
Be careful not to spill the coolant on the red- hot parts of the engine: it may catch fire and send out invisible flames.
In case maintenance operations are to be performed, it is advisable to use latex gloves.
Do not use the vehicle if the coolant is below the minimum prescribed level“MIN”.
Check the coolant level before starting off and every 2,000 km (1,250 mi) (CHECKING AND RESTORING THE
COOLANT LEVEL). Renew the coolant every two years (RENEWING THE COOLANT).
The coolant is made up of 50% water and 50% antifreeze.This mixture is ideal for most running temperatures and
ensures good protection against corrosion.
It is advisable to keep the same mixture also in the hot season, since in this way losses due to evaporation are
reduced and it is not necessary to top up very frequently.
The mineral salt deposits left in the radiator by evaporated water are thus reduced and the efficiency of the cooling
system remains unchanged.
If the outdoor temperature is below 0°, check the cooling circuit frequently and if necessary increase the antifreeze
concentration (up to maximum 60%).
For the cooling solution use distilled water, in order not todamage the engine.
Engine coolant (recommended):
PARAFLU 11 FE (diluted).
Alternatively, use brand-name coolants with performance complying with or exceeding the specifications.
Antifreeze fluid based on monoethylene glycol, CUNA NC 958-16.
NOTE Different antifreezes have different characteristics. The degree of protection provided by each product is
specified on its label.
CAUTION
Only use nitrite-free antifreeze and anticorrosive providing protection to temperatures of at least -35° C
(31° F).
chap. 1
Release 00
2002-09
1-7
1
General Information
Atlantic 500
CARBON MONOXIDE
Whenever the engine needs to be run in order to carry out some operation, ensure that this is done in the open air
or in a well-ventilated room.
Never run the engine in a closed environment unless the place is equipped with an exhaust system.
WARNING
Exhaust gases contain carbon monoxide, a poisonous gas that may cause fainting or even death.
Run the engine in an open space or in a closed space equipped with an exhaust system.
HIGH TEMPERATURE COMPONENTS
WARNING
The engine and the exhaust components reach high temperatures during use and remain hot for some time
even after the engine has been switched off.
Before handling these components, put on insulating gloves or wait for the engine and the exhaust system
to cool down.
RUNNING-IN RULES
WARNING
After the first 1,000 km (625 mi), carry out the checking operations indicated in the column “After runningin” of the Regular Service Intervals Chart, see REGULAR SERVICE INTERVALS CHART, in order to avoid
hurting your-self or other people and/ or damaging the vehicle.
The running- in of the engine is primary to ensure its working life and its correct functioning. If possible, drive on
hilly roads and/or roads with many bends, so that the engine, the suspensions and the brakes
undergo a more effective running-in.
NOTE Only after the first 1,000 km (625 mi) of running-in it is possible to obtain the best speed and acceleration
performance from the vehicle.
Keep to the following indications:
• Do not open the throttle completely if the speed is low, both during and after the running-in.
• 0-100 km (0-62 mi)
During the first 100 km (62 mi) put on the brakes with caution, avoiding sharp and prolonged brakings.
This ensures a correct bedding-in of the pads on the brake disc.
• 0-500 km (0-312 mi)
During the first 500 km (312 mi), do not exceed the 80% of the maximum allowed speed.
• Avoid driving at constant speed for long distances.
• After the first 1,000 km (625 mi), progressively increase the speed until reaching the highest performance levels.
1-8
Release 00
2002-09
chap. 1
General Information
Atlantic 500
PRECAUTIONS AND GENERAL INFORMATION
When repairing, disassembling and reassembling the vehicle, scrupulously observe the following recommendations.
WARNING
The use of open flames is forbidden under all circumstances.
Before performing any servicing or checks, switch off the engine, remove the ignition key, allow the engine
and the exhaust system to cool down, and if possible lift the vehicle on solid level flooring using specific
equipment.
To avoid burns, pay special attention to hot engine and exhaust parts.
The vehicle is made up of inedible parts.
Non mordere, succhiare, masticare o ingerire nessuna parte dello stesso per nessun motivo.
Unless otherwise specified, the reassembly of parts is carried out by following the disassembling procedures in reverse order.
Avoid running the engine in closed or poorly ventilated places.
Petrol is highly flammable and explosive. Handle with the utmost care.
Never use fuel as a solvent to clean the vehicle.
When two or more people are working at the same time, pay attention to the safety of each of them.
– Only use GENUINE aprilia spares.
– Only use the recommended lubricants.
– Where provided, use the special tools designed for this type of vehicle.
– Start tightening the screws and nuts with a greater diameter or the inner ones, in a crosswise manner.
– Carefully clean the disassembled components using a detergent with a low degree of flammability.
– Lubricate the parts (when possible) before reassembling.
– Check that every component has been fitted properly.
– Always replace the gaskets, gas rings, piston rings, O rings and split pins with new ones.
– Mark the position on all the junction points (tubes, cables, etc.) before separating them.
Use different and clear identification marks as each part must be easily recognisable during the assembling
operations.
CAUTION
Never reuse circlips.
Always replace removed circlips with new ones.
When fitting a new circlip, take care not to part its ends more than is required to fit it on the shaft.
After fitting a circlip, ensure that it is fully and firmly inserted in its seat.
SPARE PARTS
Only use Genuine aprilia Spares.
All Genuine aprilia Spares are high-quality parts specially designed and manufactured for aprilia vehicles.
CAUTION
Using NON-genuine aprilia spares may result in damage and poor performance.
chap. 1
Release 00
2002-09
1-9
1
General Information
Atlantic 500
TECHNICAL DATA
DIMENSIONS
Max. length
Max. width
Max. height (front part of the fairing included)
Seat height
Distance between centres
Min. ground clearance
Weight ready for starting
2270 mm (89.4 in)
720 mm (28.3 in)
1450 mm (57.0 in)
780 mm (30.7 in)
1575 mm (62.0 in)
150 mm (5.9 in)
200 Kg (440.9 lbs)
ENGINE
4-stroke single-cylinder, 4 valves, single camshaft in cylinder
head controlled by chain system on the flywheel side
4
1
460 cm3 (28.0 cu.in)
92 mm / 69 mm (3.6 in / 2.7 in)
10.5 : 1
electric
1450 ± 50 rpm(rpm)
automatic, dry centrifugal clutch
gear automatic
forced-circulation by means of a trochoidal pump (inside the
crankcase), oil filter and bypass for pressure adjustment
liquid cooling, forced circulation with centrifugal pump
Type
Number of valves
Number of cylinders
Total displacement
Bore / stroke
Compression ratio
Starting
Engine idling rpm
Clutch
Change
Lubrication system
Cooling
TRANSMISSION
Speed change gear
Primary
Secondary
automatic stepless
V-belt
gears
short 1/11.988
long 1/4.86
Total engine/wheel ratio
CAPACITIES
Fuel (reserve included)
Fuel reserve
Engine oil
- engine oil change and engine oil filter replacement only
- change for engine overhaul
Transmission oil
Coolant
(50% water + 50% antifreeze with ethylene glycol)
Front fork oil
Seats
Vehicle max. load
(driver + luggage)
Vehicle max. load
(driver + passenger + luggage)
17 l (4.48 gal)
4 l (1.05 gal)
1500 cm3 (91.5 cu.in)
1700 cm3 (103.7 cu.in)
~ 250 cm3 (15.25 cu.in)
1.5 l (0.39 gal)
220 cm3 (13.42 cu.in) (for each rod)
2
105 Kg (231.4 lbs)
180 Kg (396.8 lbs)
THROTTLE BODY
Model
Choke tube
1-10
Ø 38 mm (1.5 in) and single injector
diameter 39 mm (1.53 in)
Release 00
2002-09
chap. 1
General Information
FUEL SUPPLY
Type
Fuel
Atlantic 500
Electronic injection by electric fuel pump
Lead free petrol (4 Stars
) with minimum octane number 95
(N.O.R.M.) and 85 (N.O.M.M.)
FRAME
Type
Steering inclination angle
Fore stroke
SUSPENSIONS
Front
Stroke
high resistance steel tubes
28°, 50’
118 mm (4.6 in)
hydraulically operated telescopic fork
100 mm (3.93 in) rear
Two double-acting hydraulic shock absorbers with preload
adjustment to five positions
100 mm (3.93 in)
Rear
Wheel stroke
BRAKES
Front
disc brake - Ø 260 mm (10.23 in) - with hydraulic transmission
disc brake - front 260 mm (10.23 in) combined with the rear
brake 220 mm (8.66 in)
Rear, combined
WHEEL RIMS
Type
Front
Rear
in light alloy
15 x 3.00
14 x 3.75
TYRES
Type
Front
Rear
STANDARD INFLATION PRESSURE
Front
Rear
INFLATION PRESSURE WITH PASSENGER
Front
Rear
tubeless
120 / 70 - 15 M/C 56R
140 / 60 - 14 M/C REINF. 64R
210 kPa (2.1 bar/30.4 psi)
230 kPa (2.3 bar/33.3 psi)
220 kPa (2.2 bar/31.9 psi)
260 kPa (2.6 bar/37.7 psi)
IGNITION
Type
Spark advance
C.D.I. / Inductive
Variable spark advance controlled by the injection power unit
SPARK PLUG
Standard
- Alternatively
Spark plug gap
CHAMPION RG6YC
NGK - CR7EKB
0.7 - 0.8 mm (0.027 - 0.031 in)
CONTINUED 
chap. 1
Release 00
2002-09
1-11
1
General Information
Atlantic 500
ELECTRIC SYSTEM
Battery
Fuses
Generator (with permanent magnet)
12 V - 14 Ah
30 - 20 - 15 - 3 A
14 V - 330 W
BULBS
Low / high beam
Front parking lights
Direction indicators
Rear parking light / stoplight
Helmet compartment light
Number plate
Dashboard light
Third stoplight
12 V - 55 W / 12 V - 35 W
12 V - 5 W
rear 16 W - front 10 W
12 V - 5 / 21 W
12 V - 3 W
12 V - 5 W
LED
12 V - 2.3 W
WARNING LIGHTS
Direction indicators
Engine oil pressure
Low beam
High beam
Low fuel
Brake pads wear
Coolant high temperature indicator
LED
LED
LED
LED
LED
LED
LED
LUBRICANT CHART
Engine oil (recommended):
SUPERBIKE 4, SAE 5W - 40 or
4T FORMULA RACING, SAE 5W - 40.
As an alternative to the recommended oil, it is possible to use high- quality oils with characteristics in compliance
with or superior to the A.P.I. SJ specifications.
Transmission oil (recommended):
F.C., SAE 75W - 90 or
GEAR SYNTH, SAE 75W - 90.
As an alternative to the recommended oil, it is possible to use high- quality oils with characteristics in compliance
with or superior to the A.P.I. GL3 specifications.
Fork oil (recommended):
F.A. 5W or
F.A. 20W; an alternative
FORK 5W or
If you wish to have an intermediate performance between the products offered,
F.A.5 W and
FORK 5W and
FORK 20W, these can be mixed as indicated below:
SAE 10W =
SAE 15W =
FORK 20W.
F.A.20W or
F. A. 5W 67% of the volume +
F. A. 20W 33% of the volume, or
FORK 5W 67% of the volume +
FORK 20W 33% of the volume.
F. A. 5W 33% of the volume +
F. A. 20W 67% of the volume, or
FORK 5W 33% of the volume +
FORK 20W 67% of the volume.
Bearings and other lubrication points (recommended):
BIMOL GREASE 481 -
GREASE SM2.
As an alternative to the recommended product, use high- quality grease for rolling bearings, working temperature
range -30 °C …+140 °C (-22 °F....+284 °F), dripping point 150 °C …230 °C (302 °F.....446 °F), high protection
against corrosion, good resistance to water and oxidation.
Protection of the battery poles: neutral grease or Vaseline.
WARNING
Brake fluid (recommended):
Use new brake fluid only.
F.F. DOT 5 (DOT 4 compatible) -
BRAKE 5.1 DOT 5 (DOT 4 compatible).
Alternatively, use brand-name fluids with performance complying with or exceeding the specifications.
Synthetic fluido SAE J1703, NHTSA 116 DOT 4, ISO 4925.
WARNING
Use only antifreeze and anticorrosive without nitrite, ensuring protection at -35° C (-31 °F) at least.
Engine coolant (recommended):
ECOBLU - 40° C COOL.
Alternatively, use brand-name coolants with performance complying with or exceeding the specifications.
Antifreeze fluid based on monoethylene glycol, CUNA NC 956-16.
1-12
Release 00
2002-09
chap. 1
General Information
Atlantic 500
TIGHTENING TORQUES TABLE
DESCRIPTION
ftlb
Nm
14.75
20
Steering stop plate screw
8.68
12
Locking ring
36.88
50
Key switch break-off screw
7.23
10
Threaded bushing
0.22
0.3
Key switch fixing screw
7.23
10
Windscreen support fixing screw
7.23
10
Windscreen support stop nut
7.23
10
Damper to frame fixing screw
7.23
10
Nut
7.23
10
Damper fixing screw, fork side
7.23
10
14.75
20
1
FRAME ASSEMBLY
Footrest fixing screw
WINDSCREEN SUPPORT ASSEMBLY
STEERING DAMPER ASSEMBLY
FOOTBOARDS ASSEMBLY
Footboard fixing screw
ENGINE MOUNT CONNECTING RODS ASSEMBLY
Socket hexagonal-head screw
59
80
Frame connecting rod pin
44.25
60
Engine connecting rod pin
44.25
60
Stand screw
33.19
45
Lower nut
22.12
30
Side stand screw
7.23
10
STAND ASSEMBLY
FRONT SUSPENSION ASSEMBLY
Nut
11.06
15
Steering series self-locking nut
79.59
110
Flanged screw
18.44
25
Screw
36.88
50
Screw
18.44
25
19.91
27
19.91
27
Screw
29.50
40
Right and left switch
1.47
2
U bolts fixing screws
7.23
10
Hexagonal-head screw
7.23
10
Vibration-damping weights fixing screws
7.23
10
18.44
25
Plate to engine fixing screw
36.88
50
Silencer fixing screw
36.88
50
Manifold clamp
7.23
10
Serpress Nut
18.44
25
Heat guard protections fixing screw
0.59
0.8
REAR SUSPENSIONS ASSEMBLY
FRONT BRAKE ASSEMBLY
Socket hexagonal-head screw
REAR BRAKE ASSEMBLY
Socket hexagonal-head screw
HANDLEBAR AND CONTROLS ASSEMBLY
ENGINE ASSEMBLY
Shock absorber support fixing screw
EXHAUST ASSEMBLY
chap. 1
Release 00
2002-09
1-13
General Information
Atlantic 500
DESCRIPTION
ftlb
Nm
Wheel pin
36.88
50
Speedometer sensor screw
0.66
0.9
Hub screw
7.23
10
110.64
150
14.75
20
7.23
10
7.23
10
7.23
10
18.44
25
7.23
10
Coil fixing screw
1.47
2
Nut
1.47
2
Rotary switch screw
7.23
10
Rotary switch screw
7.23
10
Harness to relay clamp
3.68
5
Reflector nut
1.10
1.5
M5 self-locking nuts fuel pump flange
2.21
3
2.21
3
2.21
3
5.90
8
5.16
7
FRONT WHEEL ASSEMBLY
REAR WHEEL ASSEMBLY
Nut
PASSENGER HANDLE SUPPORTS ASSEMBLY
Passenger handles support fixing screw
PASSENGER SEAT BACK SUPPORT ASSEMBLY
Seat back support fixing screw
HEADLIGHT CARRIER BOW LOWER SUPPORT ASSEMBLY
Seat back support fixing screw
WINDSCREEN SUPPORT ASSEMBLY
Windscreen support self-locking nut
PASSENGER HANDLES ASSEMBLY
Passenger handle fixing screw
BUMPER TUBES ASSEMBLY
STAINLESS STEEL flanged screw
ELECTRICAL COMPONENTS ASSEMBLY
COOLING SYSTEM ASSEMBLY
Sleeve clamps
FILTER BOX ASSEMBLY
Sleeve clamps
SEAT ASSEMBLY
Seat hinge nut
FUEL TANK ASSEMBLY
Nut
1-14
Release 00
2002-09
chap. 1
Periodic Maintenance Operations
Atlantic 500
2
Periodic Maintenance
Operations
chap. 2
Release 00
2002-09
2-1
Periodic Maintenance Operations
Atlantic 500
This section describes the operations to be performed
periodically when servicing the main vehicle components.
CAUTION
Before performing any servicing or checks, switch
off the engine, remove the key, allow the engine
and the exhaust system to cool down, and if
possible lift the vehicle on solid level flooring
using specific equipment.
To avoid burns, be sure to keep away from hot
engine and exhaust parts.
NOTE to refit the components follow the reverse
procedure, unless otherwise specified.
PERIODIC MAINTENANCE PROGRAMME
To maintain the vehicle in perfect running order,
aprilia recommends observing the scheduled maintenance intervals for the various components.
CAUTION
ENGINE CODE
2-2
BELT REPLACEMENT
8106810
6,000 Km (3,750 mi)
8106983
12,000 Km (7,500 mi)
Release 00
2002-09
chap. 2
Periodic Maintenance Operations
Atlantic 500
PERIODIC MAINTENANCE SCHEDULE
TO BE PERFORMED BY aprilia authorized dealer
End of running-in
1,000 km (625 mi)
COMPONENTS
Accelerator cable (adjustment)
Variator belt
Steering bearings and steering
Wheel bearings
Engine oil filter
Clutch shoes - clutch housing
Valve clearance
Braking systems
Cooling system
Stop light switches
Brake fluid
Coolant
Engine oil
Fork oil
Transmission oil
Variator rollers and variator plastic guides
Wheels/ tyres and inflation pressure
Nut, bolt, screw tightening
Brakes fluid bleeding
Fuel pipes
Fuel filter
Battery/ electrolyte level
Spark plug
Carburation - slow running
Air cleaner
Accelerator operation
Brake locking operation
Light system
Light direction - operation
Suspensions
Engine oil pressure warning light
Front and rear brake pad wear
C
C
Every 6,000 km
Every 12,000 km
(3,750 mi) or 8 months (7,500 mi) or 16 months
C
S (code 8106810)
C
C
S (code 8106983)
2
every 6,000 km (3,750 mi): S
C
C
R
every 18,000 Km (11,250 mi)
C
C
C
C
C
every 6,000 km (3,750 mi): C / every 2 years: S
every 2,000 km (1,250 mi): C / every 2 years: S
every 3,000 km (1,875 mi): C / every 6,000 km (3,750 mi): S
every 30,000 km (18,750 mi) or 4 years: S
S
C
every 24,000 km (15,000 mi): S
C
every 16,000 km (10,000 mi): C
C
C
C
C
C
every 4 years: S
every 24,000 km (15,000 mi): C every 48,000 km (30,000 mi):S
C
C
C
S
C
P
C
C
C
C
C
every 18,000 km (11,250 mi):S
C
C
C
C
C
C
on every start: C (*)
every 2,000 km (1,250 mi): C
(*) to check, see TABLE OF INSTRUMENTS AND INDICATORS
C = check and clean, adjust, lubricate or replace as necessary; P = clean; S = renew; R = adjust.
The above operations must be performed at shorter intervals if the vehicle is used in rainy or dusty areas, or on rough
roads.
chap. 2
Release 00
2002-09
2-3
Periodic Maintenance Operations
Atlantic 500
LUBRICATING POINTS
KEY TO LUBRICATION CHART
A proper lubrication is important to ensure the correct
operation and duration of the vehicle components.
1)
2)
3)
4)
5)
6)
7)
NOTE Before proceeding with lubrication, thoroughly
clean all the components to remove any traces of
oxidation, grease, dirt and dust. All exposed parts that
are subject to rust must be lubricated with engine oil
or grease. Please refer to the TABLE OF LUBRICANTS.
Brake lever pin
Steering bearings
Sidestand pivot
Central stand pivot
Throttle control
Throttle cable
Rear axle
■ = Grease
▲ = Oil
The points to lubricate are shown in the LUBRICATION CHART.
LUBRICATION CHART
1
2
4
3
1
5
6
7
2-4
Release 00
2002-09
chap. 2
Periodic Maintenance Operations
Atlantic 500
BATTERY
Carefully read (PRECAUTIONS AND GENERAL
INFORMATION).
Check the electrolyte level and the tightening of the
terminals after the first 1,000 km (625 mi) and then
every 6,000 km (3,750 mi).
2
WARNING
The electrolyte in the battery is toxic and caustic
and if it gets in contact with the skin it can cause
burns, since it contains sulphuric acid. Wear
protection clothes, a face mask and/ or goggles
during maintenance operations.
In case of contact with the skin, rinse with plenty
of water.
In case of contact with the eyes, rinse with plenty
of water for fifteen minutes, then consult an
doctor without delay.
If the electrolyte is accidentally swallowed, drink a
lot of water or milk, then continue drinking milk of
magnesia or vegetable oil and consult a doctor
without delay.
The battery gives off explosive gases; keep it
away from flames, sparks, cigarettes and any
other source of heat.
During the recharging or the use, make sure that
the room is properly ventilated and avoid inhaling
the gases released during the recharging.
WARNING
Never invert the connection of the battery cables.
Do not incline the vehicle too much, in order to
avoid dangerous leaks of the battery fluid.
KEEP AWAY FROM CHILDREN.
Connect and disconnect the battery with the
ignition switch in position “ ”.
Connect first the positive cable (+) and then the
negative cable (-).
Disconnect following the reverse order.
The electrolyte is corrosive.
Do not pour or spill it, especially on the plastic
parts.
chap. 2
Release 00
2002-09
2-5
Periodic Maintenance Operations
Atlantic 500
REMOVING THE BATTERY COVER
3
Read through paragraph BATTERY.
4
NOTE Put the vehicle on a solid and flat surface
•
•
•
•
•
•
•
Make sure the ignition lock switch is turned to “ ”.
Lift the saddle, see (UNLOCKING/ LOCKING THE
SEAT).
Remove the mat from the helmet compartment.
Unloose and remove the two screws (1).
Remove the battery cover from the bottom (2)
paying attention to the upper tangs (3).
Disconnect the electrical connector (4) of the
helmet compartment light.
Remove the battery cover (2)
2
1
CHECKING AND CLEANING THE TERMINALS
•
•
–
–
Remove the battery cover, see (REMOVING THE
BATTERY COVER).
5
6
Make sure that the cable terminals (5) and the
battery terminals (6) are:
in good conditions (and not corroded or covered
with deposits);
covered with neutral grease or Vaseline.
If necessary:
• Disconnect first the negative (–) and then the
positive cable (+).
• Brush with a wire brush to eliminate any sign of
corrosion.
• Reconnect first the positive (+) and then the
negative cable (–).
• Cover the terminals of the cables and of the
battery with neutral grease or Vaseline.
WARNING
Tighten the clamp screws.
2-6
Release 00
2002-09
chap. 2
Periodic Maintenance Operations
Atlantic 500
REMOVING THE BATTERY
•
•
•
•
•
Remove the battery cover, see (REMOVING THE
BATTERY COVER).
Remove the battery breather pipe (7).
Remove the battery (8) from its seat by slightly
turning it to the right, as shown by the arrow.
Disconnect first the negative (–) and then the
positive cable (+).
Remove the battery (8) from its compartment and
put it on a flat surface, in a cool and dry place.
8
7
2
WARNING
Once it has been removed, the battery must be
stored in a safe place and kept away from children.
•
Refit the battery cover, see (REMOVING THE
BATTERY COVER).
CAUTION
Handle with care to prevent the electrolyte leakage.
LONG INACTIVATY OF THE BATTERY
Read through the paragraphs BATTERY.
When the vehicle is to remain inactive for a long
period, remove the battery and place it in a cool and
dry place. Fully charge the battery with a slow recharge.
If the battery is left on the vehicle, disconnect the
cables from the terminals.
Check the charge periodically (about once a month)
during the winter or when the vehicle is left inactive, to
prevent the battery from deteriorating.
chap. 2
Release 00
2002-09
2-7
Periodic Maintenance Operations
Atlantic 500
CHECKING THE ELECTROLYTE LEVEL
To check the electrolyte level, proceed as follows:
• Remove the battery cover, see (REMOVING THE
BATTERY COVER).
• Make sure that the fluid level is included between
the two “MIN” and “MAX” notches stamped on the
battery side.
Otherwise:
• Remove the element plugs.
CAUTION
Top up with distilled water only. Do not exceed the
“MAX” mark, since the electrolyte level increases
during the recharge.
•
Top up by adding distilled water.
RECHARCING THE BATTERY
•
•
•
•
•
•
•
Remove the battery, see (REMOVING THE
BATTERY). Remove the element plugs.
Remove the element plugs.
Check the electrolyte level, see beside (CHECKING THE ELECTROLYTE LEVEL).
Connect the battery with a battery charger.
A recharge with an amperage equal to 1/10th of
the battery capacity is recommended.
After the recharging operation, check the electrolyte level again and if necessary top up with
distilled water.
Put back the element plugs.
CAUTION
Reassemble the battery only 5-10 minutes after
disconnecting the recharger, since the battery
continues to produce gas for a short lapse of time.
2-8
Release 00
2002-09
chap. 2
Periodic Maintenance Operations
Atlantic 500
INSTALLING THE BATTERY
•
•
Remove the battery cover, see (REMOVING THE
BATTERY COVER).
Put the battery in its container.
1
CAUTION
Always connect the battery breather pipe, to
prevent the sulphuric acid vapours from corroding
the electric system, painted parts, rubber elements or gaskets when they exit the breather pipe
itself.
•
•
•
•
2
Connect, in order, the positive (+) and negative (–)
cable.
Cover the terminals of the cables and of the
battery with neutral grease or Vaseline.
Connect the battery breather pipe (1).
Refit the battery cover, see (REMOVING THE
BATTERY COVER).
SPARK PLUG
Read through the paragraphs MAINTENANCE.
1
2
Check the spark plug every 6,000 km (3,750 mi) and
replace every 12,000 Km (7,500 mi).
Periodically remove the spark plug, eliminate any
carbon deposits and change it if necessary.
To reach the spark plug:
• Remove the left inspection cover, see (REMOVING THE RIGHT AND LEFT INSPECTION COVERS).
To remove and clean the spark plug:
WARNING
Before carrying out the following operations, let
the engine and the exhaust silencer cool down
until they reach room temperature, in order to
avoid burns.
• Move the coolant pipe (1) to gain access to the
spark plug.
• Disconnect the cap (2) from the spark plug high
voltage cable.
• Remove all the dirt from the base of the spark
plug, then unscrew it with the spanner you will find
in the tool kit and extract it from its seat, taking
care that neither dust nor other substances enter
the cylinder.
• Make sure that there are neither carbon deposits,
nor corrosion marks on the electrode and on the
central porcelain part; if necessary, clean them
with the special cleaners for spark plugs, with an
iron wire and/or a metal brush.
chap. 2
Release 00
2002-09
2-9
Periodic Maintenance Operations
Atlantic 500
•
Energetically blow some air, in order to prevent
the removed residues from getting into the engine.
If the spark plug has crackings on the insulating
material, corroded electrodes or excessive deposits, it must be changed.
• Check the spark plug gap with a thickness gauge.
The gap must be 0.7 – 0.8 mm (0.027 - 0.031 in);
if necessary adjust it, carefully bending the earth
electrode.
• Make sure that the washer is in good conditions.
With the washer on, screw the spark plug by hand
in order not to damage the thread.
• Tighten the spark plug by 1/2 turn as to compress
the washer, using the spanner found in the tool kit.
Spark plug driving torque:
12 - 14 Nm (1.2 - 1.4 kgm).
0.7
– 0.8mm
mm
0,7-0,8
(0.027
0.031
in)
(0.027-0.031 in)
CAUTION
The spark plug must be well tightened, otherwise
the engine may overheat and be seriously damaged. Use the recommended type of spark plug
only, see TECHNICAL DATA, in order not to compromise the life and performance of the engine.
•
•
Correctly fit the spark plug to prevent it from
disconnecting due to the engine vibrations.
Refit the left inspection cover, see (REMOVING
THE RIGHT AND LEFT INSPECTION COVERS).
Standard
Spark plug
CHAMPION RG6YC
- Alternatively
NGK - CR7EKB
Spark plug gap
0.7 - 0.8 mm
(0.027 - 0.031 in)
ADJUSTING
THE THROTTLE CONTROL
4
3
Read through the paragraphs MAINTENANCE.
The idle stroke of the throttle grip must be 2 - 3 mm
(0.078 - 0.118 in), measured on the edge of the grip
itself.
If this is not the case, proceed as follows:
• Position the vehicle on the centre stand.
• Withdraw the protection element (1).
• Loosen the lock nut (2).
• Rotate the adjuster (3) in such a way as to restore
the prescribed value.
• After the adjustment, tighten the lock nut (2) and
check the idle stroke again.
• Put back the protection element (1).
• Cable (4) opens the throttle
• Cable (5) closes the throttle.
1
2
WARNING
After the adjustment, make sure that the rotation
of the handlebar does not modify the engine idling
rpm and that the throttle grip returns smoothly
and automatically to its original position after
being released.
2-10
Release 00
2002-09
chap. 2
5
Periodic Maintenance Operations
Atlantic 500
AIR FILTER
1
Read through the paragraphs MAINTENANCE.
The air cleaner should be inspected and cleaned
every 6,000 km (3,750 mi), depending on the conditions of use.
If the vehicle is used on dusty or wet roads, the
cleaning operations should be carried out more
frequently.
2
2
To clean the filtering element it is necessary to remove
it from the vehicle.
REMOVAL
• Position the vehicle on the centre stand.
• Lift the saddle (SADDLE LOCKING / UNLOCKING).
• Remove the safety clamp (1).
• Pull out the pin (2) fixing the piston to the air filter
cover, as shown in the figure.
3
3
CAUTION
When removing the pin, hold the saddle to prevent
it from falling.
• Hold the saddle, unloose and remove the six
screws (3) fixing the air filter cover to the plastic
under the saddle.
4
CAUTION
When lifting the air filter cover, take care not to
detach the intake sleeve from the filter box.
• Carefully lift the air filter cover (4).
• Remove the air filter (5).
5
4
CLEANING
WARNING
Do not use petrol or inflammable solvents to wash
the filtering element, in order to avoid fires or
explosions.
Do not use any additives or liquids for cleaning as
to prevent the forming of moisture inside the filter
box. Only use compressed air.
• Clean the filtering element (5) with a jet of air.
4
CAUTION
DO NOT OIL THE FILTERING ELEMENT in order
not to compromise the filter and engine correct
operation.
4
CAUTION
5
Refit the filter (5) in the filter cover (4) (make sure
the gasket adheres perfectly to its seat), tighten
the cover to the filter box.
chap. 2
Release 00
2002-09
2-11
Periodic Maintenance Operations
Atlantic 500
ENGINE OIL
Check the engine oil after the first 1,000 km (625 mi)
or at the end of the running in period, and then every
3,000 km (1,875 mi). Change the oil every 6000 km
(3,750 mi), see RENEWING THE ENGINE OIL AND
ENGINE OIL FILTER.
NOTE Use oil with specifications 5/W 40, see (TABLE OF LUBRICANTS).
CAUTION
When topping up the engine oil, never exceed the
“MAX” mark.
CHECKING AND RESTORING THE ENGINE OIL
LEVEL
Carefully read LUBRICANTS, MAINTENANCE and
LUBRICANT CHART.
CHECK
NOTE Position the vehicle on firm and flat ground.
•
Position the vehicle on the centre stand.
WARNING
1
The engine and the components of the exhaust
system become very hot and remain hot for some
time after the engine has been stopped. Before
handling these components, wear insulating
gloves or wait until the engine and the exhaust
system have cooled down.
•
2
Switch off the engine, let the oil flow into the
crankcase and allow the engine and the oil to cool
down.
NOTE The non-performance of the operations described above may result in the incorrect measurement of the engine oil level.
• Unscrew and extract the plug/ dipstick (1).
• Clean the part in contact with the oil with a clean
cloth.
• Tighten the plug/ dipstick (1) completely, screwing
it into the filling hole (2).
• Withdraw the plug/ dipstick (1) again and read the
oil level on the dipstick itself:
3
1
MAX
MAX = maximum level;
MIN = minimum level.
The difference between “MAX” and “MIN” is about: –
400 cc (24.4 cu.in)
• The level is correct if the oil reaches approx. the
“MAX” mark on the dipstick.
2-12
Release 00
2002-09
chap. 2
MIN
Periodic Maintenance Operations
Atlantic 500
Never exceed the “MAX” mark, nor leave the oil
below the “MIN” mark, in order to avoid serious
damage to the engine.
• If necessary, provide for topping up.
4
TOPPING UP
• Pour a small quantity of oil in the filling hole (2)
and wait about one minute, so that the oil flows
uniformly into the oil pan.
• Check the oil level and top up if necessary.
• Top up by adding small quantities of oil, until
reaching the prescribed level.
• At the end of the operation, screw and tighten the
plug/ dipstick (1).
2
WARNING
Do not use the vehicle with insufficient lubrication
or with contaminated or unsuitable lubricants,
since this would accelerate the wear of the moving parts and may also cause irreparable failures.
RENEWING THE ENGINE OIL AND
THE ENGINE OIL FILTER
Check the engine oil level every 3,000 km (1,875 mi),
see (CHECKING THE ENGINE OIL LEVEL AND
TOPPING UP).
NOTE Use oil with specifications 5/W 40, see (TABLE OF LUBRICANTS).
When topping up the engine oil, never exceed the
“MAX” mark.
Check the engine oil after the first 1,000 km (625 mi)
and then:
–
–
every 6,000 km (3,750 mi), renew
every 3,000 km (1,875 mi), check level/top up.
NOTE Put the vehicle on a solid and flat surface
•
Put the vehicle on the central stand.
WARNING
The engine and the components of the exhaust
system become very hot and remain hot for some
time after the engine has been stopped. Before
handling these components, wear insulating
gloves or wait until the engine and the exhaust
system have cooled down.
•
Switch off the engine, let the oil flow into the
crankcase and allow the engine and the oil to cool
down.
chap. 2
Release 00
2002-09
2-13
Periodic Maintenance Operations
Atlantic 500
NOTE Make sure the above procedures are carried
1
before the engine oil level is checked
•
•
2
Unscrew and remove cap/dipstick (1).
Unloose and remove the engine oil cartridge filter
(3).
WARNING
Do not use the vehicle if lubrication is insufficient.
Never use unsuitable or contaminated lubricants
as they accelerate the wear and tear of moving
parts and can cause irreparable damage.
3
4
WARNING
The used oil contains substances that are to the
detrimental of the environment. Dispose of the
used oils in compliance with the regulations in
force.
•
•
•
•
•
•
Unloose and remove the oil drain plug (4) to allow
the engine oil to flow out completely.
Fit a new oil cartridge filter (3) after having lubricated the relative O rings.
Screw and tighten the engine oil drain plug (4).
Pour in about 1700 cm3 (103.7 cu.in) of engine oil
through the filling hole (2).
Screw and tighten the oil dipstick (1).
Start the vehicle and let the engine run for a few
minutes. Switch it off and allow it cool down.
Check the engine oil level again with dipstick (1). If
necessary, top up without exceeding the MAX
mark.
Top up and change the oil using SAE synthetic oil
5/W 40 exceeding the API ST specifications.
CHECKING THE TRANSMISSION OIL LEVEL AND
TOPPING UP
1
Read through the paragraphs LUBRICANTS, MAINTENANCE AND TABLE OF LUBRICANTS.
NOTE Put the vehicle on a solid and flat surface
• Put the vehicle on the central stand.
WARNING
The engine and the components of the exhaust
system become very hot and remain hot for some
time after the engine has been stopped. Before
handling these components, wear insulating
gloves or wait until the engine and the exhaust
system have cooled down.
2-14
Release 00
2002-09
chap. 2
Periodic Maintenance Operations
•
•
•
•
Atlantic 500
Unscrew and remove cap/dipstick (1).
Clean dipstick with a clean cloth.
Completely screw the cap-dipstick (1) into the
filling hole (2).
Remove the cap-dipstick (1) again and check the
oil level:
1
MAX
MIN
MAX = maximum level
MIN = minimum level
•
2
The oil level is correct when it reaches the “MAX”
mark on the dipstick.
CAUTION
The oil level should never exceed the “MAX” mark
or go below the “MIN” mark in order to prevent
serious damages to the engine.
•
Top up if necessary.
TOPPING UP
• Pour a small amount of oil in the filling hole (2)
and wait until the oil starts flowing into the crankcase.
• Check the oil level, top up if necessary.
• Add small quantities of oil until the prescribed level
is reached.
• Afterwards, screw and tighten the cap-dipstick (1).
SAE80W/90 OIL EXCEEDING THE API GL3 SPECIFICATIONS.
WARNING
Do not use the vehicle if lubrication is insufficient.
Never use unsuitable or contaminated lubricants
as they accelerate the wear and tear of moving
parts and can cause irreparable damage.
chap. 2
Release 00
2002-09
2-15
Periodic Maintenance Operations
Atlantic 500
RENEWING THE TRANSMISSION OIL
Read through the paragraph LUBRICANTS, MAINTENANCE and TABLE OF LUBRICANTS.
1
NOTE Put the vehicle on a solid and flat surface.
•
Put the vehicle on the central stand.
CAUTION
Do not use the vehicle if lubrication is insufficient.
Never use unsuitable or contaminated lubricants
as they accelerate the wear and tear of moving
parts and can cause irreparable damage.
CAUTION
The used oil contains substances that are to the
detrimental of the environment. Dispose of the
used oils in compliance with the regulations in
force.
CAUTION
The engine and the components of the exhaust
system become very hot and remain hot for some
time after the engine has been stopped. Before
handling these components, wear insulating
gloves or wait until the engine and the exhaust
system have cooled down.
•
•
•
•
•
•
Switch off the engine, let the oil flow into the
crankcase and allow the engine and the oil to cool
down.
Unscrew and remove the cap-dipstick (1).
Unscrew and remove the drain nut (2).
Let the oil flow into a container with capacity of at
least 300 cm3 (18.3 cu.in).
Screw and tighten the drain nut (2).
Top up as described under paragraph (CHECKING THE TRANSMISSION OIL LEVEL AND
TOPPING UP).
2
DISC BRAKES
NOTE This vehicle is provided with front and rear
disc brakes, with separate hydraulic circuits.
CAUTION
The following information refers to a single braking system, but is valid for both.
Any sudden play variations or elastic resistance
of the brake lever is due to the hydraulic system
failure.
CAUTION
Check that the brake disck and the frictional
gaskets are not greasy, in particular after having
performed maintenance or check operations.
Check that the brake tube is not twisted or worn.
KEEP OUT OF REACH OF CHILDREN.
DO NOT DISPOSE OF THE LIQUID IN THE ENVIRONMENT.
2-16
Release 00
2002-09
chap. 2
Periodic Maintenance Operations
Atlantic 500
CAUTION
The brakes are the parts that most ensure your
safety and for this reason they must always be
perfectly working; check them before every trip.
A dirty disc soils the pads, with consequent
reduction of the braking efficiency. Dirty pads
must be replaced, while dirty discs must be
cleaned with a high-quality degreaser.
2
Renew the brake fluid every two years.
NOTE This vehicle is provided with front and rear
disc brakes, with separate hydraulic circuits.
The following information refers to a single braking
system, but is valid for both.
When the disc pads wear out, the brake fluid level in
the reservoir decreases to automatically compensate
for their wear.
The brake fluid reservoirs are located under the
handlebar cover, next to the brake lever connections.
Periodically check the brake fluid level in
the reservoirs, see beside (CHECK) and the wear of
the pads, see (CHECKING THE PADS WEAR).
WARNING
Do not use the vehicle if the braking system leaks
fluid.
CHECK
To check the level:
NOTE Put the vehicle on a solid and flat surface.
•
•
•
Put the vehicle on the central stand.
Turn the handlebar so that the fluid in the brake
fluid reservoir is at the same level as the “MIN”
mark shown on the glass (1).
Check that the fluid in the resevoir exceeds the
“MIN” mark shown on the glass (1).
MIN = minimum level.
if the fluid does not reach at least the “MIN” mark:
CAUTION
The level of the fluid gradually decreases with pad
wear.
•
1
Check the brake pads (CHECKING THE PADS
WEAR) and the disc wear.
CAUTION
Check the braking efficiency.
If the brake lever stroke is excessive or if the
braking efficiency becomes poor, it may be necessary to bleed the system.
chap. 2
Release 00
2002-09
2-17
Periodic Maintenance Operations
Atlantic 500
RESTORING THE BRAKE FLUID LEVEL
Read through the paragraph DISC BRAKES.
Remove the four screws (2) from brake fluid reservoir
(3).
Remove cover (4).
4
2
2
NOTE To avoid spilling the brake fluid when topping
up, ensure that the fluid in the reservoir is parallel with
the reservoir rim (in a horizontal position).
Remove the gasket under the cover.
NOTE To fill the reservoir to the MAX level, ensure
1
that the rim of the brake fluid reservoir is parallel with
the ground and add fluid until sight (5) is completely
covered.
3
CAUTION
Top up to the MAX level only if the brake pads are
new.
The level of the fluid gradually decreases with pad
wear.
Topping up to the MAX level when the pads are
worn will cause the brake fluid to overflow when
the pads are replaced.
Fill reservoir (3) with brake fluid (see LUBRICANT
CHART) until sight (1) is completely covered.
To refit the components, follow the reverse procedure
to the removal.
CHECKING BRAKE PAD WEAR
Read through the paragraph DISC BRAKES.
The following information are referred to one
braking system only, but are valid for both.
Check the brake pad wear after the first 1,000 km (625
mi) and successively every 2,000 km (1,250 mi).
The wear of the brake pads depends on the use, on
the kind of drive and on the road.
The wear is heavier when driving on dirty or wet
roads.
FRONT BRAKE CALIPER
– Front side from the bottom for both calipers.
REAR BRAKE CALIPER
– Rear side from the bottom for both pads (C).
WARNING
The excessive wear of the friction material would
cause the contact of the pad metal support with
the disc, with consequent metallic noise and
production of sparks from the caliper; braking
efficiency, safety and soundness of the disc would
thus be negatively affected.
•
If the thickness of the frictional material (also of
one pad only) becomes 1.5 mm (0.059 in), replace
both pads (both front and rear pad).
2-18
Release 00
2002-09
chap. 2
Periodic Maintenance Operations
Atlantic 500
BLEEDING THE BRAKING SYSTEM
(FRONT SIDE ONLY)
Read through the paragraph DISC BRAKES.
Any air present in the brake circuit acts as a cushion,
absorbing much of the pressure applied by the brake
pump and reducing the effectiveness of the brake
caliper. The presence of air is indicated by a spongy
feel of the brake lever and a reduction in the braking
action.
2
CAUTION
In view of the danger for both the rider and the
vehicle, it is essential that the hydraulic circuit
should be bled after reinstalling the brakes and
restoring the braking system to its normal operating conditions.
4
Loosen the four screws (2) on brake fluid reservoir (3).
Remove the cap (4).
2
2
NOTE To avoid spilling the brake fluid when topping
up, be sure to keep the fluid in the reservoir parallel
with the ground.
Remove the gasket above the cover.
Check if the brake fluid completely covers sight (6), and
if necessary top up.
Remove the cap from breather valve (7).
Connect a transparent pipe (9) to breather valve (8).
3
6
CAUTION
Take care not to soil the pads or the disc with
brake fluid.
Place the free end of the transparent pipe in a container (10).
Slowly pull the brake lever 2-3 times to the end of its
travel and then keep it pulled.
Loosen breather valve (8), press the lever and check
if any air bubbles come out of the transparent pipe
with the brake fluid.
CAUTION
Before releasing the brake lever, retighten
breather valve (8) so as to prevent air from getting
into the brake circuit.
When the brake fluid comes out with no air bubbles,
tighten breather valve (8) and then release the brake
lever.
Tightening torque for breather valve (8):
14 Nm (1.4 kgm).
NOTE Repeat the last three operations until all the
air has been purged.
CAUTION
After refitting the parts, repeatedly operate the
brake lever and ensure that the braking system is
working properly.
chap. 2
Release 00
2002-09
2-19
Periodic Maintenance Operations
Atlantic 500
BLEEDING THE INTEGRAL BRAKING SYSTEM
Read through the paragraph DISC BRAKES.
The air present in the hydraulic circuit acts as a cushion, absorbing much of the pressure applied by the brake
pump and reducing the effectiveness of the caliper during the braking.
The presence of air can be noticed by a spongy feel of
the brake lever and poor braking action.
WARNING
In view of the danger for both the rider and the
vehicle, it is essential that the hydraulic circuit
should be bled after reinstalling the brakes and
restoring the braking system to its normal operating conditions.
NOTE The lever of the l.h. pump acts either on the
rear caliper and on the right front caliper.
Loosen the four screws (1) on brake fluid reservoir (2).
Remove the cap (3).
NOTE To avoid spilling the brake fluid when topping
up, be sure to keep the fluid in the reservoir parallel
with the ground.
1
3
1
2
With the specific tool (6), suck the oil through the
breather pipe (4) of the right front caliper (5) by
unscrewing the breather pipe (4) nut by half turn.
4
5
Add oil in the brake fluid reservoir (2) for about 2-3
times.
6
2-20
Release 00
2002-09
chap. 2
Periodic Maintenance Operations
Atlantic 500
Unloose and remove the three screws (7).
Remove the rear brake caliper (8) of the plate (9) and
the relevant cable lead.
Fit the rear brake caliper (8) so that the breather valve
(10) is in the highest position.
8
9
7
2
7
With the specific tool, suck the oil through the breather
valve (10) of the rear brake caliper (8) by unscrewing
the breather valve (10) nut by half turn.
10
Add oil in the brake fluid reservoir (2) for about 2-3
times.
CAUTION
Never allow the fluid reservoir (2) to empty completely, to prevent air from entering the circuit.
8
6
Refit the rear brake caliper. Remove the front hood,
see (REMOVING THE FRONT HOOD).
With the specific tool, suck the oil through the retarder
(12) breather (11), by unscrewing the breather (11) nut
by half turn.
11
12
Operate the brake lever until the reservoir is
completely free from air bubbles.
Refit the cover (3) of the brake fluid reservoir (2).
Refit the front hood, see (REMOVING THE FRONT
HOOD).
NOTE Perform the bleeding again if the braking
action is poor.
chap. 2
Release 00
2002-09
2-21
Periodic Maintenance Operations
Atlantic 500
CHECKING AND RESTORING THE COOLANT
LEVEL
2
Read through the paragraphs COOLANT and
PRECAUTIONS AND GENERAL INFORMATION.
MAX
CAUTION
Do not use the vehicle if the coolant is below the
minimum prescribed level “MIN”.
MIN
Check the coolant level every 2,000 km (1,250 mi)
and after long trips; have the coolant changed every
16 months.
DO NOT DISPOSE OF THE FLUID IN THE ENVIRONMENT
Put the vehicle on the central stand.
Remove the front hood, see (REMOVING THE
FRONT HOOD).
Check that the coolant level in the expansion tank (2)
is between the “MIN” and “MAX” mark (see figure).
WARNING
Do not remove the expansion tank plug (1) when
the engine is hot, since the coolant is under
pressure and its temperature is high.
If it gets in contact with the skin or with clothes it
may cause severe burns and/or damage.
Contrariwise, unscrew and the remove the filler cap
found under the front hood. Add coolant until it roughly
reaches the “MAX” level.
Do not exceed the maximum level as this would cause
the coolant to overflow during the engine operation.
Replace the filler cap.
Replace the front hood.
CAUTION
In case of excessive consumption of coolant and
in case the tank remains empty, make sure that
there are no leaks in the circuit.
The coolant is harmful: DO NOT INGEST.
KEEP OUT OF REACH OF CHILDREN.
CAUTION
Only use antifreeze and anticorrosive fluid free
from nitrite, ensuring protection at a temperature
of at least –35°C (–31°F).
2-22
Release 00
2002-09
chap. 2
Periodic Maintenance Operations
Atlantic 500
RENEWING THE COOLANT
Read through the paragraphs COOLANT and
PRECAUTIONS AND GENERAL INFORMATION.
1
CAUTION
Do not use the vehicle if the coolant is below the
minimum level.
Check the level of the coolant every 2,000 km (1,250
mi) and after long journeys. Renew the coolant every
16 months.
2
CAUTION
Switch off the engine and allow the engine and the
exhaust system to cool down.
DO NOT DISPOSE OF THE COOLANT IN THE ENVIRONMENT
Put the vehicle on the central stand.
Remove the front hood, see (REMOVING THE
FRONT HOOD).
Remove the splash guard, see (REMOVING THE
SPLASH GUARD).
2
MAX
MIN
CAUTION
Do not remove the expansion tank cap when the
engine is hot. The coolant is under pressure at
high temperatures and can cause burns and/or
damage clothes.
Remove filler cap (1) from expansion tank (2).
Place a container with a capacity of at least 1500 cm3
(91.5 cu.in) under the crankcase, below drain screw.
Unloose and remove the screw clamp (3), disconnect
the union.
Drain all the coolant into the container and then pour it
into another container for liquid recovery.
Replace the union and fix with clamp (3).
Pour 1200 cm3 (73.2 cu.in) of coolant in the expansion
tank (2).
Add coolant until it roughly reaches the “MAX” level
Do not exceed the maximum level as this would cause
the coolant to overflow during engine operation.
Replace filler cap (1).
Remove the right inspection cover, see (REMOVING
THE RIGHT AND LEFT INSPECTION COVER).
4
3
CAUTION
Exhaust gases are harmful.
Avoid running the engine in closed or poorly
ventilated places.
chap. 2
Release 00
2002-09
2-23
Periodic Maintenance Operations
•
•
Atlantic 500
Start the engine and let it idle.
Place a container under the engine to gather any
coolant coming out of breather screw (5).
5
6
CAUTION
The coolant in the circuit is under pressure. To
avoid dangerous spurts, loosen breather screw (5)
slowly and moderately.
• Loosen breather screw (5) on thermostatic valve
(6); allow a moderate quantity of coolant to flow
out together with any air bubbles and then tighten
breather screw (5).
• Check the level of the fluid in expansion tank (2)
and then top up to the MAX level (see page 2-25
CIRCUIT BLEEDING for the bleeding).
• Ride a few kilometres until the engine reaches the
normal operating temperature.
CAUTION
Switch off the engine and allow the engine and the
exhaust system to cool down.
To refit the plastic parts follow the reverse procedure.
CAUTION
If coolant consumption is excessive, or if the
coolant runs out in the tank, check for possible
leakage from the circuit.
The coolant is harmful: DO NOT INGEST
KEEP OUT OF REACH OF CHILDREN
CAUTION
Only use nitrite-free anticorrosive and antifreeze
agents providing a protection at temperatures of
-35° C (-31° F) or lower
For more information on the cooling system, see
(COOLING SYSTEM).
2-24
Release 00
2002-09
chap. 2
Periodic Maintenance Operations
Atlantic 500
CIRCUIT BLEEDING:
• Remove the front hood, see (REMOVING THE
FRONT HOOD).
• Remove the filter box, see (REMOVING THE
FILTER BOX).
• Open the expansion tank cap.
• Remove the breather cap located on the cylinder
head “T” union (1).
•
•
•
2
3
2
1
Connect a transparent rubber pipe (2) between
the breather pipe and the expansion tank.
Screw breather nut (3) by 1/2 turn.
Add coolant in the expansion tank (4) up to the
max level (check level through the glass in the
front compartment).
2
4
•
•
•
•
Switch on the engine.
The air bubbles will start coming out of the circuit
through the transparent pipe (2).
Check that the pipe between the expansion tank
and the radiator starts spraying liquid into the
expansion tank (visible from the front side). In this
case, it means that the thermostatic valve is open
and the circuit is completely full.
Close the bleeder valve.
NOTE If the heater fan turns on it is unimportant as
the sensor that activates the fan is located on the
cylinder head and not on the radiator.
CHECKING AND ADJUSTING THE STEERING
CHECKING THE BEARINGS PLAY
Read through the paragraph PRECAUTIONS AND
GENERAL INFORMATION.
Periodically check the play existing on the steering.
To carry out this operation, proceed as follows:
Position the vehicle on the centre stand.
Shake the fork in the riding direction (see figure).
If any play is found, adjust.
chap. 2
Release 00
2002-09
2-25
Periodic Maintenance Operations
Atlantic 500
ADJUSTING THE BEARINGS PLAY
Remove the legshield, see (REMOVING THE
LEGSHIELD).
Unloose the check nut (1).
CAUTION
To avoid damaging the steering bearings, take
care not to tighten adjusting nut (2) forcefully.
1
Turn in adjusting nut (2) until the play of the bearings
is eliminated.
Check the play by shaking the fork in the direction of
motion and ensuring that the steering can rotate freely
and smoothly.
While holding adjusting nut (2) in position, tighten
counternut (1) with a spanner
Tightening torque for counternut (1):
110 Nm (11 kgm).
2
Repeat the last but one step.
STEERING DAMPER
It is possible to adjust the steering damper when
riding the vehicle at full load (driver + passenger +
luggage).
To carry out this operation, proceed as follows:
Turn the ring nut (1) clockwise to increase the damper
brake.
1
CAUTION
Tighten the ring nut to increase the damper adjusting brake, thus increasing the effort required
for turning the handlebar, which becomes less
easy to handle.
CHECK ENGINE PIN BUSHINGS
Read through the paragraph PRECAUTIONS AND
GENERAL INFORMATION.
Periodically check the slack existing between the
engine pin bushings.
To carry out this operation, proceed as follows:
Position the vehicle on the centre stand.
Shake the wheel transversally with respect to the
riding direction.
If any play is found, check that all fulcrum axis fasteners are securely tightened (see REMOVING THE
ENGINE LINKAGE).
2-26
Release 00
2002-09
chap. 2
Periodic Maintenance Operations
Atlantic 500
CHECKING THE FRONT SUSPENSION
Read through the paragraph PRECAUTIONS AND
GENERAL INFORMATION.
Inspect the front suspension after the first 1,000 km
(625 mi) and then every 6,000 km (3,750 mi) or 8
months.
Renew the oil in the front suspension every 12,000 km
(7,500 mi), see FRONT SUSPENSION.
Check that no oil is leaking from the fork, and that the
outside surface of the fork rods is not scratched or
grooved. Replace any damaged parts.
Also perform the following checks:
While pulling the front brake lever, repeatedly stroke
the fork by pushing down on the handlebar. The fork
should move smoothly, and there should be no traces
of oil on the fork rods.
Check the tightening of all parts and the function of the
front suspension joints (see FRONT SUSPENSION).
2
CHECKING THE REAR SUSPENSION
Read through the paragraph PRECAUTIONS AND
GENERAL INFORMATION.
Inspect the rear suspension after the first 1,000 km
(625 mi) and subsequently every 6,000 km (3,750 mi)
or 8 months.
Check that no oil is leaking from the shock absorbers.
Check the tightening of all parts and the function of
the rear suspension joints (see REAR SUSPENSION).
CAUTION
Check that both shock absorbers are adjusted to
the same position. See (ADJUSTMENT).
ADJUSTING THE REAR SUSPENSION
Read through the paragraph PRECAUTIONS AND
GENERAL INFORMATION.
The rear suspension consists of a doubleeffect shock
absorber (braking with compressed/extended shock
absorber) fixed to the engine by means of a silentblock.
The standard adjustment, set by the manufacturer, is
suitable for a driver weighing about 70 kg (154.3 lbs).
If your weight and needs are different, adjust the ring
nut (1) with the appropriate spanner provided in the
tool kit, thus setting the ideal travelling conditions (see
table).
1
CAUTION
Adjust both shock absorbers to the same position
chap. 2
Release 00
2002-09
2-27
Periodic Maintenance Operations
Atlantic 500
ADJUSTMENT OF THE REAR
SUSPENSION SPRING PRELOAD
Adjusting
ring
Function
Attitude
Rotation
(arrow A)
Spring
preload
increase
The vehicle
is more rigid
RecomSmooth or
mended
normal roads
kind of road
Notes
Drive with
passenger
Rotation
(arrow B)
Spring
preload
decrease
The vehicle
is less rigid
Roads with
uneven
surface
Drive
without
passenger
WHEELS AND TYRES
Read through the paragraph PRECAUTIONS AND
GENERAL INFORMATION.
WHEELS INSPECTION
Check that the wheel rims are not cracked or distorted. If necessary replace them.
Check the radial runout of the wheel.
If the wheel is distorted beyond the acceptable limit,
check the condition of the rim and the bearings.
If necessary replace the wheel.
Runout limits:
Vertical runout: 2 mm (0.078 in)
Lateral runout: 2 mm (0.078 in)
Check the wheel trim.
Slowly turn the wheel several times and observe the
point at which it stops.
If the wheel is not statically balanced, it will always
stop at the same point. Fit a balancing weight at the
lightest point (top).
TYRES
Read through the paragraph PRECAUTIONS AND
GENERAL INFORMATION.
This vehicle is provided with tubeless tyres.
WARNING
Periodically check the tyre inflation pressure at
room temperature, see (TECHNICAL DATA).
If the tyres are hot, the measurement is not correct.
Carry out the measurement especially before and
after long rides.
If the inflation pressure is too high, the ground
unevenness cannot be dampened and is therefore
transmitted to the handlebar, thus compromising
the driving comfort and reducing road holding
during turns.
2-28
Release 00
2002-09
chap. 2
Periodic Maintenance Operations
Atlantic 500
If, on the contrary, the inflation pressure is too
low, the tyre sides (1) are under greater stress and
the tyre itself may slip on the rim or it may become loose, with consequent loss of control of
the vehicle.
In case of sudden braking the tyres could even get
out of the rims.
Further, the vehicle could skid while turning.
1
2
Check the surface and the wear of the tyres, since
tyres in bad conditions can impair both the grip
and the controllability of the vehicle.
Some types of tyres homologated for this vehicle
are provided with wear indicators.
There are several kinds of wear indicators.
Visually check if the tyres are worn and in this
case have them changed.
If the tyres are old, even if not completely worn
out, they may become hard and may not ensure
good road holding.In this case, have the tyres
changed.
Change the tyre when it is worn out or in case of
puncture on the tread side, if the puncture is
larger than 5 mm (0.196 in).
After repairing a tyre, have the wheels balanced.
Use only tyres in the size suggested by aprilia,
see TECHNICAL DATA.
Do not install tyres with air tube on rims for tubeless tyres and viceversa.
Make sure that the tyres always have their valve
sealing caps on, to prevent them from suddenly
going flat.
Change, repair, maintenance and balancing operations are very important and should be carried out
by qualified technicians with appropriate tools.
If the tyres are new, they may still be covered with
a slippery film: drive carefully for the first miles.
Do not oil the tyres with unsuitable fluids.
chap. 2
Release 00
2002-09
2-29
Periodic Maintenance Operations
Atlantic 500
MINIMUM TREAD DEPTH LIMIT (2)
front:............2 mm [0.078 in] (
rear:.........2 mm [0.078 in] (
3 mm) [0.118 in]
3 mm) [0.118 in]
2
Do not exceed the max transportable weight as this
would compromise the vehicle’s stability, handiness
and may cause damages to the tyres.
MAX LOAD 180 Kg (396.8 lbs)
TYRES PRESSURE
FRONT
RIDER ONLY
REAR
2.1 bar (30.4 psi) 2.3 bar (33.3 psi)
FULL LOAD
2.2 bar (31.9 psi) 2.6 bar (37.7 psi)
(passenger + driver)
According to the tests carried out by aprilia, only the
tyres listed below have been approved for this model:
MANUFACTURER
SIZE
MODEL
FONT
MICHELIN
REAR
FONT
REAR
2-30
CHENG SHIN
MAXXIS
120/70-15’ 56S
140/60-14’ 64S
GOLD STANDARD
GOLD STANDARD
120/70-15’56R
140/60-14’ 64R
M-6002
M-6002
Release 00
2002-09
chap. 2
Engine
Atlantic 500
3
Engine
chap. 3
Release 00
2002-09
3-1
Engine
Atlantic 500
COMPONENTS THAT CAN BE REMOVED
WITHOUT REMOVING THE ENGINE
5
The following parts can be removed and refitted without removing the engine from the frame.
9
UPPER SIDE
- Throttle body (1) see (THROTTLE BODY)
- Intake manifold sleeve (2)
- Starter motor (3)
- Coolant temperature thermistor (4) (on cylinder head)
- Injector (5)
1
4
FRONT SIDE
- Tappet cover (6)
- Head (7)
- Cylinder (8)
10
RIGHT SIDE
- Oil pressure sensor (9)
- Engine oil filter (10)
- Exhaust silencer (11) see (REMOVING THE EXHAUST SILENCER)
- Water pump (12)
- Ignition casing (13)
- Flywheel
- Stator coil
- Pulse generator (pick-up)
11
12
13
LEFT SIDE
- Driving belt box air filter
- Transmission crankcase cover (14)
- Speed variator assembly
- Clutch assembly
- Drive belt
Unless otherwise specified, for information on removing procedures refer to the ENGINE WORKSHOP
MANUAL n°1063 , n°1064 , n°1065 , n°1066
, n°1067
and n°1068 .
3
14
6
7
3-2
2
Release 00
8
2002-09
chap. 3
Engine
Atlantic 500
REMOVING THE ENGINE FROM THE FRAME
1
3
Read through the paragraph (PRECAUTIONS AND
GENERAL INFORMATION).
5
2
6
CAUTION
Switch off the engine and allow the engine and the
exhaust system to cool down.
Disconnect the battery.
Completely empty out the coolant circuit (RENEWING
THE COOLANT).
Remove the right and left inspection covers, see
(REMOVING THE RIGHT AND LEFT INSPECTION
COVER).
4
7
3
CAUTION
Clean the outside of the engine with a brush, rags
and a degreasing detergent.
Take care not to damage rubber and plastic parts
with corrosive or penetrating detergents and
solvents.
If a steam cleaner is required, take care not to
direct any high-pressure water or air jet, or any
steam jet towards the following parts: wheel hubs,
controls on the left and right sides of the handlebar, brake pump, instruments and indicators,
silencer exhaust, document holder, ignition
switch/steering lock.
Clean the engine and the related components.
CAUTION
To ensure proper refitting of the parts, suitably
mark the wires, sleeves, pipes, etc.
On reassembly, make sure that all the parts are
correctly fitted.
Unloose and remove screw (1) fixing the injector
supply pipes support (2).
Detach the two connections (3) supplying fuel to the
injector.
Detach the injector electrical connection (4).
Detach the automatic starter electrical connection (5).
Detach the electrical connection (6) from the sensor
detecting the position of the throttle body throttle.
Remove the spark plug (7) and release the relative
cable.
Disconnect the electrical connection from the air temperature sensor of the throttle body.
chap. 3
Release 00
2002-09
3-3
Engine
Atlantic 500
Detach the water inlet pipe (8) to the pump by
unloosing screw (9) on hose clamp (10).
8
10
9
Detach the water outlet pipe (11) from the cylinder by
unloosing screw (12) on hose clamp (13) found on the
union above the cylinder.
13
15
12
11
Detach the electrical connection (14) of the coolant
temperature sensor (15).
14
Unloose the two nuts (16) fixing the cable guides to
the throttle body support.
Remove the cable guide and relevant control delivery
barrel (17) on the throttle body.
Remove the cable guide and the relevant control
return barrel (18) on the throttle body.
17
18
16
Detach the electrical connection (19) from the phase
sensor (20) and release the wires from the clamps
fixing them to the frame.
20
19
3-4
Release 00
2002-09
chap. 3
Engine
Atlantic 500
Remove rubber protection (21) and detach the
engine oil pressure sensor wire connector (22).
21
22
3
Unloose and remove the nut fixing the starter relay
cable (23) and remove the cable (24).
Unloose and remove the two screws (25) fixing the
starter to the crankcase, and release the cables for
the ground.
Detach connector (26) of the injection positive cable.
23
26
24
25
WARNING
Owing to the weight and bulk of the components
and the vehicle, the following operations are to be
performed in cooperation with a second operator.
Before starting work, the two operators should
agree on their respective roles in the operations to
be performed (in the following instructions “A”
operations are to be carried out by the 1st operator and “B” operations by the 2nd operator), on
the procedures to be followed and on any warning
signs to be placed.
EXERCISE EXTREME CAUTION.
WARNING
The weight and bulk of the vehicle can cause
dangerous unbalancing and tipping of the vehicle
during the hoisting phase.
PROCEED WITH CAUTION AND MAKE SURE YOU
CAN BEAR THE WEIGHT OF THE VEHICLE.
Remove the rear wheel, see (REMOVING THE REAR
WHEEL).
“A” Lift the vehicle from its rear side, fasten up the
wheel with belts if necessary.
chap. 3
Release 00
2002-09
3-5
Engine
Atlantic 500
“A” arrange for suitable supports to be placed under
the engine for the next positioning, after the frame
removal.
“B” unscrew and remove pin (27) fixing the left rear
suspension (28).
Keep the nut and the washer.
28
CAUTION
Since the engine is heavy, proceed with caution. In
particular, mind the hands.
27
“A” carefully lean the engine on the floor.
“B” unscrew and remove the left pin (29) fixing the
engine to the frame. Keep the washer.
“A” hold the left side of the engine.
29
“B” unscrew and remove the right pin (30) fixing the
engine to the frame. Keep the washer.
CAUTION
Proceed with caution.
In particular, mind the limbs and fingers.
Proceed with caution when lifting and moving the
engine.
30
“A” and “B” Lean the engine assembly on the work
bench.
CAUTION
Close the engine intake manifold in order to
prevent dirt and foreign bodies from getting in.
3-6
Release 00
2002-09
chap. 3
Fuel System
Atlantic 500
4
Fuel System
chap. 4
Release 00
2002-09
4-1
Fuel System
Atlantic 500
FUEL TANK AND PUMP
EMS FUEL INJECTION SYSTEM
The fuel injection system used is of the integrated fuel injection and ignition type.
Fuel is injected indirectly into the manifold by means of the electroinjector.
Fuel injection and ignition are timed on a 4-stroke cycle via a phonic wheel keyed to the cam shaft control and a
reluctance variation sensor.
Fuel supply and ignition are controlled in relation to the engine revolutions and the opening of the throttle control.
Further corrections are carried out on the basis of the following parameters:
- Coolant temperature
- Air intake temperature
- Environmental pressure
The system carries out a idling supply correction on a cold engine via a stepper motor inserted on to a by-pass
circuit of the throttle valve. The control unit controls the stepper motor and the timing of the injector opening, thus
guaranteeing idling stability and correct fuel supply.
Under all working conditions, fuel supply is controlled by modifying the injector opening time.
Petrol supply pressure is kept constant on the basis of environmental pressure.
The supply circuit is composed of:
- Fuel pump
- Fuel filter
- Injector
- Pressure regulator
The pump, filter and regulator are inserted into the fuel tank via a single support.
The injector is connected by means of two snap-connector tubes. This allows continuous circulation and avoids the
risk of fuel overheating. The pressure regulator is situated at the end of the circuit. The fuel pump is controlled by
the EMS control unit; thus guaranteeing vehicle safety.
The ignition circuit is composed of:
- H.V. coil
- H.V. cable
- Shielded cap
- EMS control unit
- Spark plug
The EMS control unit controls ignition with optimum advance, at the same time guaranteeing 4-stroke cycle timing
(ignition only during compression phase).
The EMS fuel injection-ignition system controls the working of the engine by means of a preset programme.
Should certain entry signals fail, an acceptable working of the engine is still guaranteed in order that the user may
reach a repairs centre.
Obviously, this will not happen if the revolutions signal fails, nor if there is an anomaly in the control circuit:
- Fuel pump
- H.V. Coil
- Injector
4-2
Release 00
2002-09
chap. 4
Fuel System
Atlantic 500
FUEL SUPPLY SYSTEM
5
3
10
4
7
6
4
8
1
9
2
KEY TO FUEL SUPPLY SYSTEM
1) Fuel pump
2) Fuel tank
3) Intake manifold
4) Fuel supply pipe (DELIVERY)
5) Fuel supply pipe (RETURN)
6) Excess fuel drain pipe
7) Injector
8) Fuel level float
9) Fuel pump filter
10) Fuel supply cap
chap. 4
Release 00
2002-09
4-3
Fuel System
Atlantic 500
MAINTENANCE
Check the condition of the fuel feed pipes every 6,000 km (3,750 mi) or 8 months.
Any pipes showing signs of desiccation, cracks or cuts must be replaced.
Ensure that the pipes are not twisted or choked.
FUEL SUPPLY CHECK
Read through paragraphs (PRECAUTIONS AND GENERAL INFORMATION) and (FUEL).
CAUTION
Fuel fumes are a health hazard.
Before proceeding, ensure that the working area is suitably aerated. Do not inhale fuel fumes.
Avoid contact of fuel with the skin.
Do not smoke or use open flames.
Do not dispose of fuel in the environment.
Put the vehicle on the central stand.
Ensure that the tank contains fuel.
Remove the central tunnel, see (REMOVAL OF CENTRAL TUNNEL).
To one side of the vehicle, place a container with an approx. 1 l capacity (0.264 gal) to collect the fuel.
CAUTION
Work with caution. Be ready to collect the fuel that exits from the fuel supply pipe (RETURN) .
Disconnect the fuel supply pipe (RETURN) from the fuel pump (5) (see SUPPLY SYSTEM diagram).
Place the free end of the pipe in the container.
Set the ignition switch to “ ” .
Without throttle, allow the starter motor to work for a few seconds and at the same time check that the fuel flows out
of the pipe (4).
If the flow is discontinuous or inexistent, verify the integrity and efficiency of the following components:
CAUTION
DO NOT INVERT THE PIPES DURING REASSEMBLY.
Mark the pipes and their attachments in order to reassemble them correctly.
Check that the pipes ARE NOT twisted and are not choked or obstructed.
To carry out checks follow instructions in WORKSHOP MANUALS n°1063
n°1067
and n°1068 .
4-4
Release 00
2002-09
, n°1064
, n°1065
chap. 4
, n°1066
,
Fuel System
Atlantic 500
FUEL PUMP REMOVAL/DISMANTLING
CAUTION
Read through the paragraphs (PRECAUTIONS AND
GENERAL INFORMATION) and (FUEL).
Work with caution during removal of the fuel
pump (5) to avoid damage to the fuel pre-filter (6).
PUMP ASSEMBLY REMOVAL
Remove the fuel pump (5) from the tank (7).
CAUTION
Fuel fumes are a health hazard.
Before proceeding, ensure that the working area
is suitably aerated. Do not inhale fuel fumes.
Avoid contact of fuel with the skin.
Do not smoke or use open flames.
Do not dispose of fuel in the environment.
Remove the central tunnel, see (REMOVAL OF
CENTRAL TUNNEL).
Disconnect the electrical control connection (1) from
the fuel pump.
Disconnect the fuel supply pipes (2) from the pump
casing.
Unscrew and remove the six nuts (3).
Remove the fuel pump fixing clamp (4).
4
2
3
2
3
4
1
5
6
7
chap. 4
Release 00
2002-09
4-5
Fuel System
Atlantic 500
FUEL PUMP AND FUEL LEVEL FEELER DISASSEMBLY AND CHECKING
For dismantling of the components refer to WORKSHOP MANUALS n°1063 , n°1064 , n°1065 ,
n°1066 , n°1067
and n°1068 .
THROTTLE BODY
1)
2)
3)
4)
5)
6)
Stepper motor
Valve position sensor
Air temperature sensor
Valve
Valve opening control cables support plate
Valve opening/closure wiring control guide
6
2
5
4-6
1
4
Release 00
2002-09
3
chap. 4
Fuel System
Atlantic 500
THROTTLE BODY REMOVAL
Read through the paragraphs (PRECAUTIONS AND
GENERAL INFORMATION) and (FUEL).
Remove the air filter box, see (AIR FILTER).
Disconnect the delivery and return fuel supply pipes
(1) to the injector.
Unscrew and remove the fixing screw (2) of the fuel
pipe clamps.
Disconnect the electrical connection (3) of the injector
control.
1
4
2
3
Disconnect the electrical connection (4) of the air
temperature sensor.
Disconnect the electrical connection (5) of the stepper
motor.
Disconnect the electrical connection (6) of the valve
position sensor.
5
4
6
Loosen the two nuts (7) that fix the cable runners to
the fuel supply support.
Pull out the cable runner and its related delivery barrel
(8) of the carburettor control.
Pull out the cable runner and its related return barrel
(9) of the carburettor control.
9
8
7
chap. 4
Release 00
2002-09
4-7
Fuel System
Atlantic 500
Unscrew and remove the three screws (10) fixing the
intake manifold (11) to the head.
Remove the intake manifold (11) including the throttle
body (12).
10
10
12
11
Unscrew and remove the three screws (13) fixing the
throttle body (12) to the intake manifold (11).
Separate the throttle body (12) from the intake manifold (11).
Remove the screw (14) fixing the injector (15) to the
Intake manifold.
Remove the injector (15) from the intake manifold
(11).
4-8
Release 00
2002-09
15
14
11
12
13
chap. 4
Cooling System
Atlantic 500
5
Cooling System
chap. 5
Release 00
2002-09
5-1
Cooling System
Atlantic 500
SYSTEM DESCRIPTION
The cooling system is constructed with a centrifugal pump coaxial to the countershaft and as such completes a
number of revolutions identical to that of the driving shaft.
The pump has two ducts, one for entry and one for exit.
The exit duct supplies the cylinder and consequently the cylinder head; the entry duct leads from the cylinder head
and its entrance to the pump is controlled by the thermostat plate.
The main stabilizer of the thermostat acts instead on the main pump entry duct leading from the radiator.
The radiator is fed from the cylinder head exit; the expansion tank is inserted parallel to the radiator with the ducts
on two levels: the delivery high up (in the air) and the fluid return low down (in the fluid).
The system thus composed is 2-way.
The first way is the internal engine circulation and involves the pump, cylinder and cylinder head; this circulation is
fully active when the thermostat is fully closed.
The second way is active with the thermostat fully open and is the main circulation which involves the pump,
cylinder, cylinder head, radiator and expansion tank; for medium openings of the thermostat, however, the two
circuits are both partially inserted, therefore the two ways are superimposed.
This kind of circuit is defined as the type with inlet thermostat. The thermostat is crossed by an inverted flow, that is
with cold water which tends to lower the temperature of the wax cell.
This system allows optimization of the engine heating phases.
The expansion tank, parallel to the radiator and inserted on the main circuit, guarantees autodraining when working.
For the filling stages of the system there is a drain exiting from the cylinder head (see filling rules).
The electrical fan is controlled by the fuel injection system with temperature measured on the cylinder head of the
engine.
COOLANT
For information concerning the coolant see (COOLANT); (CHECKING AND TOPPING UP OF THE COOLANT) and
(REPLACING COOLANT) in the related WORKSHOP MANUALS n°1063 , n°1064 , n°1065 , n°1066 ,
n°1067
and n°1068 .
2
10
3
1
8
4
9
Key
1) Radiator/pump pipe
2) Thermostat valve
3) Pump/head cylinder pipe
4) Cylinder head/pump pipe
5) Radiator
6) Cylinder head/radiator pipe
7) Expansion tank
8) Expansion tank/radiator
pipe
9) Electrical fan
10) Water pump casing
7
6
5
5-2
Release 00
2002-09
chap. 5
Cooling System
Atlantic 500
RADIATOR REMOVAL
Read through the paragraphs (COOLANT) and
(PRECAUTIONS AND GENERAL INFORMATION).
1
Drain the coolant completely, see (REPLACING
COOLANT), in the WORKSHOP MANUALS n°1063
, n°1064 , n°1065 , n°1066 , n°1067
and
n°1068 .
1
Remove the legshields, see (LEG SHIELDS REMOVAL ).
Remove the front splash guard, see (SPLASH
GUARDS REMOVAL).
Remove the thermo-reflecting material.
Disconnect the three pipes (1) on the radiator.
Unscrew and remove the two fixing screws (2) of the
radiator.
3
2
1
5
CAUTION
Work with caution. Do not damage the radiator
cooling fins.
Remove the radiator (3) lightly turning it clockwise,
and pull towards the left side of the vehicle.
ELECTRICAL COOLING FAN REMOVAL
1
3
Read through the paragraph (PRECAUTIONS AND
GENERAL INFORMATION).
Remove the radiator, see (RADIATOR REMOVAL).
Disconnect the electrical fan connection (1).
Unscrew and remove the three screws (2) fixing the
electrical fan to the support (3).
Remove the electrical fan (4).
chap. 5
2
4
Release 00
2002-09
5-3
Cooling System
Atlantic 500
EXPANSION TANK REMOVAL
Read through paragraphs (COOLANT) and (PRECAUTIONS AND GENERAL INFORMATION).
Place the vehicle on its central stand.
Remove the front hood, see (FRONT HOOD REMOVAL).
Remove the legshields, see (LEGSHIELDS REMOVAL).
Remove the dash board, see (DASHBOARD REMOVAL).
CAUTION
DO NOT DISPOSE OF COOLANT IN THE ENVIRONMENT.
On removing the hose (1) any coolant present will
exit from the expansion tank (2).
Be ready with a container with capacity of approx.
1 litre to collect the liquid on exit.
Place an absorbent cloth under the expansion tank
to collect any coolant that may be dispersed.
NOTE Keep a supply of hose clamps to replace the
7
3
2
4
6
5
1
originals (of a special kind without screws).
Remove the clamp (3). Replace with a new one during
reassembly.
Pull the hose (4) out from the expansion tank attachment.
Remove the clamp (5). Replace with a new one during
reassembly.
Pull out the hose (1) from the expansion tank attachment.
Quickly place the container under the expansion tank
to collect the coolant.
CAUTION
Coolant is hazardous to health.
Keep the container in a safe place.
DO NOT LEAVE WITHIN REACH OF CHILDRENI
Unscrew and remove the two screws (6) and screw
(7).
Remove the expansion tank.
5-4
Release 00
2002-09
chap. 5
Cooling System
Atlantic 500
THERMOSTAT VALVE
For information concerning the thermostat valve, see
WORKSHOP MANUALS n°1063 , n°1064 ,
and n°1068 .
n°1065 , n°1066 , n°1067
COOLANT PUMP
5
For information concerning the coolant pump, see
WORKSHOP MANUALS n°1063 , n°1064 ,
n°1065 , n°1066 , n°1067
and n°1068 .
COOLANT THERMISTOR
For information concerning the coolant thermistor, see
WORKSHOP MANUALS n°1063 , n°1064 ,
n°1065 , n°1066 , n°1067
and n°1068 .
chap. 5
Release 00
2002-09
5-5
Cooling System
5-6
Atlantic 500
Release 00
2002-09
chap. 5
Electrical Equipment
Atlantic 500
6
Electrical Equipment
chap. 6
Release 00
2002-09
6-1
Electrical Equipment
Atlantic 500
CHECKING THE RECHARGING SYSTEM
The following key will help the reader to consult this
section.
CABLE COLOURS
Ar
orange
Az
light blue
B
blue
Bi
white
G
yellow
Gr
gray
M
brown
N
black
R
red
V
green
Vi
violet
Ro pink
CHECKING THE RECHARGING VOLTAGE
• Check the electrolyte level (CHECKING THE
ELECTROLYTE LEVEL).
• Check the battery voltage (RECHARGING THE
BATTERY).
• Start the engine and rev it up to 5000 rpm (throttle
twist grip rotated by approximately 1/4 of its
travel).
• Set the lights switch in the “ ” position and the
lights selector switch in the “ ” position.
• Using a pocket multimeter, measure the direct
voltage between the positive (+) and negative (-)
terminals of the battery.
• If the multimeter reads voltages of less than 13 V
or more than 15 V:
• check the no-load operation and continuity of the
alternator (CHECKING THE ALTERNATOR NOLOAD OPERATION) and (CHECKING THE
ALTERNATOR CONTINUITY) and the voltage
regulator (VOLTAGE REGULATOR).
17
24
37
19
1
1
Key to second figure
17) Voltage regulator
19) Battery
37) Ignition switch (right switch)
24) Main fuse
Standard charging voltage: 13 - 15 V (c.c.) at 5000
rpm.
CHECKING THE ALTERNATOR NO-LOAD
OPERATION
• Remove the right side panel, see (REMOVAL OF
THE SIDE PANELS).
• Detach regulator wiring connector (1).
• Start the engine and rev it up to 5000 rpm
(throttle twist grip rotated by approximately 1/4 of
its travel).
• Using a pocket multimeter, alternately measure
the a.c. voltage between the three yellow wires
(G). If the multimeter readings are less than 50 V,
the alternator is faulty.
Standard no-load voltage: more than 50 V (a.c.)
at 5000 rpm.
6-2
Release 00
2002-09
chap. 6
Electrical Equipment
Atlantic 500
CHECKING THE ALTERNATOR CONTINUITY
With motor off:
• Remove the right side panel, see (SIDE PANELS
REMOVAL).
• Detach regulator wiring connector (1).
• Using a pocket multimeter, check continuity
between stator yellow wires (G).
• Also check the insulation of the stator support.
1
1
Standard resistance: 0.1 - 1 Ω
Standard resistance between stator support and
wiring: ∞ (infinite resistance)
VOLTAGE REGULATOR
• Remove the tail panel, see (TAIL PANEL
REMOVAL).
• Remove the right side panel, see (SIDE PANELS
REMOVAL).
• Disconnect the connectors (1) and (2).
• Using a pocket multimeter (1 kΩ scale) on the
regulator side, measure the resistance between
the wires shown in the table below.
• If the measured resistance is not as specified,
replace the regulator.
6
Multimeter positive (+) terminal on:
1
Multimeter negative (-) terminal on:
1
2
3
4
5
6
7
∞
∞
∞
∞
∞
∞
∞
∞
∞
∞
∞
∞
∞
∞
∞
∞
0
∞
∞
0
2
∞
3
∞
∞
4
∞
∞
∞
5
∞
∞
∞
∞
6
∞
∞
∞
0
∞
7
∞
∞
∞
∞
0
1
2
∞
∞
CAUTION
4
This is a rough measuring method. If possible,
verify the recharging process by using another
regulator which has been checked to be in
working order
chap. 6
7
6
Release 00
5
2002-09
1 3
2
6-3
Electrical Equipment
Atlantic 500
FUEL INJECTION SYSTEM
INJECTION SUPPLY WIRE DIAGRAM
37
R/Gr
R/N
35
1
V/N
R/Bi
R/Gr
R/Gr
Ar/N
Ar/V
24
B 15A V/N
C 15A
E 3A V/R
A 15A V/R
D 15A
F
STAND
SPIA
CAVALLETTO
SWITCH
R/Bi
1
2
3
4
R/B
5
6
7
8
9
10
11
12
13
14
15
16
Ar/N
17
18
19
20
21
22
23
24
25 Gr/N
26
V/R
52
E.C.U.
CONTROL
UNIT
CENTRALINA
E.C.U.
R/N
1
R
B
M/N
M/V
Gr/N
R/B
R/M
Ar/V
1
1
2
5
3
N
N
V
M
INIETTORE POMPA
FUEL
FUEL
BENZINA
BENZINA
INJECTOR PUMP
9
10
19
11
Key to wire diagram
9) Main injection relay
10) Secondary injection relay
11) Side stand switch
19) Battery
35) Key switch
37) Right switch
52) E.C.U. Control unit
Release 00
2002-09
R
R
1
85
86
87
30
R/M
R/M
R/M
M/N
R/N
Gr/N
Ar/V
N
BOBINA
COIL
6-4
R 30A V/R
R 20A R/Bi
1
chap. 6
22
Electrical Equipment
Atlantic 500
STAND SWITCH CONTROL
Rotation of the side stand (1) must be free from
obstruction.
Carry out the following checks:
•
•
The springs (2) must not be damaged, worn, rusty
or weakened.
The stand must turn freely, by greasing the joint if
necessary, see (TABLE OF LUBRICANTS).
On the side stand (1) there is a safety switch (3) with
the role of preventing or interrupting engine running
with the side stand (1) lowered.
To check that the safety switch is working (3):
•
•
•
•
6
Sit on the saddle in driving position.
Raise the side stand (1).
Start the engine.
With the throttle twistgrip released and the motor
idling, lower the side stand (1) which should
activate the safety switch (3).
At this point:
- the engine should stop;
- on the dashboard the side stand lowered indicator
“ “ should light up.
If this does not happen, replace the switch (3).
STAND SWITCH
Cables
Position
N
V
N
Lowered
Raised
chap. 6
Release 00
2002-09
6-5
Electrical Equipment
Atlantic 500
INJECTION RELAY CONTROLS
To verify that the relay is working:
•
•
•
Remove the seat, see (REMOVING THE SEAT).
Supply a 12 V tension to the two male terminals
(85-86).
With a multimeter (in ohm meter mode) verify the
continuity between the other two terminals (8730).
Correct value with supply to the relay: 0 Ω
Correct value without supply to the relay: ∞ Ω
If the resulting values do not correspond to those
prescribed, replace the relay concerned.
CAUTION
For the main injection relay only:
Observe the polarity supplying terminal (86) with
the “+” and terminal (85) with the “-”, as in the
interior there is a diode.
6-6
Release 00
2002-09
chap. 6
Electrical Equipment
Atlantic 500
IGNITION/INJECTION SYSTEM
E.C.U. CONNECTIONS
43
!
x1000r/min
mp/h
Km/h
EFI
ABS
SET
TRIP
FAN
RELE VENTOLA
RELAY
36
M/Bi
3
4
5
6
7
Az/R
Ar
R/B
Vi
B
9
10
11
12
13
14
15
16
M
R
M/G
B/N
Gr/R
Az
Az/V
Ro/G
6
R
M
1
B
54
4
2
3
POMPA
FUEL
BENZINA
PUMP
Gr
Ar
Ar/R
Bi/N
Gr
Ro/N
Gr
M/Bi
M/G
R/M
R/M
Gr/R
1
Ar/Bi
R/M
Az
Ro
G
Vi
1
Gr/N
R/B
R/M
18 Ro/N
Vi/N
19
Ar/Bi
20
G
21
Gr
22
23 N
24 Ro
25 Gr/N
26
N
52
E.C.U.
CONTROL
UNIT
CENTRALINA
E.C.U.
Ro/G
Gr
Bi/N
N
N
Bi/N
N
Az/V
Az/R
N
N
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Ar/R
W
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
RELE
INJECTOR
INIEZIONE
SECONDARIO
RELAY
13
6
14
15
Key to wire diagram
2) Revolutions sensor
3) Stepper motor
4) Coil
6) Fuel injector
13) Accelerator sensor
14) Engine air thermistor
15) Dashboard/engine water thermistor
36) Drop sensor
43) Dashboard
52) E.C.U.Control unit
chap. 6
Release 00
2002-09
6-7
Electrical Equipment
Atlantic 500
1
2
3
4
6
5
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
CAUTION
Since inside the C.D.I. control unit there are diodes, condensers and other electrical components, the
measuring method described is approximate.
Further checking is recommended by replacing the control unit with another pre-checked to ensure it is in
working order, or carry out the checks described in the chapter (ELECTRICAL SYSTEM CONTROL USING A
C.D.I. CONTROL UNIT CONNECTOR).
6-8
Release 00
2002-09
chap. 6
Electrical Equipment
Atlantic 500
CONNECTIONS TO THE E.C.U. CONTROL UNIT
COMPONENT
TERMINALS
NOMINAL
VALUE
CABLE COLOUR
RPM sensor
7 - 12
680 Ω
B - B/N
Stepper Motor
14 - 24
52 Ω
Az - Ro
Stepper Motor
6 - 21
52 Ω
Vi - G
Accelerator sensor
1 - 22
5 kΩ
M/Bi - Gr
Accelerator sensor
1 - 11
1 - 6 kΩ
M/Bi - M/G
Air injection terminals
18 - 22
see tab.
Ro/N - Gr
Water injection terminals
4 - 22
see tab.
Ar - Gr
Drop sensor
16 -22
62 kΩ *
Ro/G - Gr
Coil
20
0.6 Ω
Ar/Bi - R/M
Injector
13
14.5 Ω
Gr/R - R/M
6
* With drop sensor in upright position.
chap. 6
Release 00
2002-09
6-9
Electrical Equipment
Atlantic 500
CHECKING THE HV COIL
• Remove the left inspection cover, see
(REMOVING THE RIGHT AND LEFT
INSPECTION COVERS).
• Disconnect terminal (1).
• Unscrew and remove the two screws (2).
• Disconnect the spark plug (3).
• Remove the coil (4).
4
3
2
1
•
•
With a pocket multimeter (scale 200 Ω), measure
the resistance (from the coil side) between the
terminals (A e B) indicated in the diagram.
If the resistance measured is not correct, replace
the coil.
Standard value: 0.6 Ω ± 0.1 Ω
•
B
A
Also verify the resistance between the high
voltage terminal and the casing of the coil.
Ω
Standard value: 7.4 kΩ
CAUTION
Before measuring, remove the H.V. cable complete
with the spark plug cap.
6-10
Release 00
2002-09
chap. 6
Electrical Equipment
Atlantic 500
DROP SENSOR CHECK
2
With motor off:
•
1
Remove the front hood, see (REMOVING THE
FRONT HOOD).
Check that the sensor (1) is mounted correctly (with
the arrow imprinted on the rubber pointing upwards).
•
•
3
Partially remove the fuse carriers (2).
Disconnect the two-way connector (3)(white/grey)
and take measurements (on terminals sensor
side).
CAUTION
6
During reassembly ensure correct coupling of the
electrical connector (3).
•
With a multimeter (scale x 100 kΩ), measure the
resistance between the black and white/black
cable terminals (N -Bi/N).
Ω ± 15%
Standard value: resistance 62 kΩ
•
Remove the sensor (1) with the rubber washer in
its housing, and lean it sideways to an angle of
more than 45° (simulating the parking position).
Standard value: 0 - 1 Ω
If the resistance is different from that prescribed,
the sensor (1) must be replaced.
•
Repeat the operations leaning the sensor towards
the opposite side.
chap. 6
Release 00
2002-09
6-11
Electrical Equipment
Atlantic 500
RPM SENSOR CHECK
With motor off:
• Disconnect the three-way connector (1) and take
measurements.
• With a multimeter (scale x 100 Ω) measure the
resistance between the sensor terminals,
observing polarity (see diagram).
1
Standard value: 680 Ω ± 10%
•
If the resistance is infinite or different from the
prescribed value, the sensor must be replaced.
+
6-12
Release 00
2002-09
chap. 6
Ω
+
Electrical Equipment
Atlantic 500
THROTTLE VALVE POTENTIOMETER
(ACCELERATOR SENSOR) CHECK
With motor off:
• Disconnect the three-way connector (black) (1).
1
CAUTION
During reassembly ensure correct coupling of the
electrical connector (1).
•
•
Set the ignition switch to “ ”.
With a multimeter (scale kΩ), measure the
resistance between the potentiometer terminals.
MEASUREMENT (A)
A
6
Resistance between the two terminals A and B, in any
position of the throttle valves:
Ω ± 10%
Standard value: 5 kΩ
B
MEASUREMENT (B)
Resistance between the terminals A and C:
From the value of the throttle completely closed,
accelerating progressively up to completely open, the
resistance will vary as follows:
C
Ω to 6 kΩ
Ω ± 10%
Standard value: from 1 kΩ
NOTE To unscrew the two screws more easily, block
with LOCTITE®243, preheat with a blow of hot air.
•
•
Unscrew and remove the screws.
Remove the potentiometer.
If the resistance values are different from those
prescribed, replace the potentiometer.
chap. 6
Release 00
2002-09
6-13
Electrical Equipment
Atlantic 500
INJECTOR CHECK
With motor off:
• Disconnect the two-way connector (1) (black) and
take measurements (on the terminals on the
injector side).
• With a multimeter (scale x 100 Ω), measure the
resistance between the injector terminals.
1
2
Standard value: 14.5 ± 10% Ω to 25°C
If the resistance is infinite (∞) or less than the
prescribed value, the injector (2) must be
replaced.
COOLANT THERMISTOR FUNCTION CHECK
•
•
•
•
•
•
Remove the thermistor (1), see (COOLANT
THERMISTOR REMOVAL).
Connect a multimeter (2) (set in ohm metre mode)
as illustrated in the diagram, to the thermistor (1).
Immerse the thermistor (1) in a container (3)
containing coolant.
In the same container immerse a thermometer (4)
with 0 -150 °C gauge (32 -302 °F).
Place the container on a hotplate (5) and slowly
heat the liquid.
Check the temperature indicated on the
thermometer (4) and the value of the thermistor
(1) indicated on the multimeter.
1
Verify that the values vary in relation to the temperature as indicated.
NOTE If the standard values do not change as the
temperature changes, or change too much from those
given in the table, replace the thermistor (1).
•
Repeat these operations also for the other
thermistor.
Temperature °C
A1 - A2 (Ω)
B1 - B2 (Ω)
60
557 ±10%
576 ±10%
90
196 ±10%
231 ±10%
120
80.6 ±10%
105 ±10%
A1
B1
B2
A2
6-14
Release 00
2002-09
chap. 6
Electrical Equipment
Atlantic 500
FUEL PUMP CHECK
•
•
(direct current)
Supply terminals 1 and 4 of the pump connector
with a 12V tension (c.c.).
Verify that the pump works, emitting the
characteristic hum, and check on the manometer
that the supply pressure reaches at least i 150
KPa (1.5 bar).
CAUTION
Observe the pump polarity.
AIR THERMISTOR FUNCTION CHECK
CAUTION
6
2
During reassembly ensure the correct coupling of
the electrical connector (1).
•
•
•
•
•
•
Remove the thermistor (2).
Connect a multimeter (3) (set to ohm meter mode)
al thermistor (2), as illustrated in the diagram.
Immerse the thermistor in a container (4)
containing water.
In the same container immerse a thermometer (5)
with 0 -150 °C gauge (32 -302 °F).
Place the container on a hotplate (6) and slowly
heat the liquid.
Check the temperature indicated on the
thermometer (5)and the value of the thermistor
indicated on the multimeter.
1
Verify that the values vary in relation to the temperature as indicated.
Temperature °C
Resistance Ω
0
9750
10
5970
20
3740
30
2410
NOTE If the values do not change as the temperature changes, or change too much from those given in
the table, replace the thermistor (2).
chap. 6
Release 00
2002-09
6-15
Electrical Equipment
Atlantic 500
STARTING AND STOP LIGHTS SYSTEM
37
34
35
R/Gr
R/N
V/G
G/R
V/G
R/N
Gr/N
V/G
33
1
R/N
B/G
B
V/G
30
85
86
87
V/N
R/Bi
55
R/Gr
Gr/N
R/N
B/G
G/R
B/G
Gr/N
1
56
1
V/G
B
V/G
B
V/G
B
V/G
B
V/G
B
24
B 15A V/N
C 15A
E 3A
A 15A V/R
D 15A
F
V/R
Ar/V
V/G
B
V/R
R/Bi
R/Gr
V/G
B
G/R
B
1
R
R
N
N
R
R
22
R/Bi
B/Bi
B
M/N
N
V
M
85
86
87
30
M/N
R/N
Gr/N
Ar/V
R
R 30A V/R
R 20A R/Bi
1
M
21
9
19
11
20
Key to wire diagram
9) Main injection relay
11) Side stand switch
19) Battery
20) Starting relay
21) Starting motor
24) Secondary fuses
33) Rear stop light switch
34) Front stop light switch
35) Key switch
37) Right switch
55) Stop lights relay
56) Third stop light bulbs
6-16
Release 00
2002-09
chap. 6
54
58
31
31
58
54
31
31
Electrical Equipment
Atlantic 500
STARTING RELAY CHECK
•
Disconnect the two-way connector (1)(white).
CAUTION
During reassembly ensure correct coupling of the
electrical connector (1).
•
•
•
•
•
1
Pull the relay out from the special hooks (2).
Pull out the two rubber protectors (3-4).
Disconnect the cables from their respective
terminals on the relay (2).
Supply the two internal terminals to the connector
(1) with a 12V tension from the relay side.
With a multimeter (set to Ohm meter mode) verify
the continuity between the two screw contacts on
the relay (2).
6
3
Correct value with supply to the relay: 0 Ω
Correct value without supply to the relay: ∞ Ω
4
If the resulting values do not correspond to those
prescribed, replace the relay (2).
2
STOP LIGHTS RELAY CHECK
To verify that the relay is working:
•
•
•
To access the relay raise the saddle and remove
the left tail lamp, see (TAIL LAMP BULBS
REPLACEMENT).
Supply the two male terminals (85-86) with a 12V
tension;
With a multimeter (set to ohm meter mode) verify
the continuity between the other two terminals (8730).
Correct value with supply to the relay: 0 Ω
Correct value without supply to the relay: ∞ Ω
If the resulting values do not correspond to those
prescribed, replace the relay concerned.
chap. 6
Release 00
2002-09
6-17
Electrical Equipment
7) ENGINE OFF BUTTON (
Cable
Rs
R/N
-
Atlantic 500
)
R/Gr
8) START BUTTON ( )
Cable
Rs
V/G
G/R
9) IGNITION BUTTON
G/Gr
G
V/N
R/Bi
ZADI
Cable
Rs
9
PUSH
10) FRONT BRAKE LIGHT SWITCH
Cable
Rs
Gr/N
V/G
ON
11) REAR BRAKE LIGHT SWITCH
Cable
Rs
V/G
R/N
ON
10 11
12) SIDE STAND SWITCH
Cable
Rs
N( )
V
M
OPEN
CLOSED
12
6-18
Release 00
2002-09
chap. 6
Electrical Equipment
Atlantic 500
ELECTRIC COOLING FAN
WIRING DIAGRAM
35
38
G/N
R/Bi
Vi/N
V
V/N
R/Bi
30
87
85
86
1
24
V
B 15A
V/N
C 15A
E 3A
A 15A
D 15A
F
6
R/Bi
Vi/N
B
G/N
22
Gr
Ar
R 30A R/Bi
1
N
E.C.U. CONTROLE.C.U.
UNIT
CENTRALINA
52
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
16
R
N
B
G/N
1
19
15
Key to wiring diagram
15) Water thermistor
16) Fan
19) Battery
24) Secondary fuses
35) Key switch
38) Fan relay
52) E.C.U. control unit
CHECKING THE ELECTRIC FAN
•
•
•
•
To check the operation of electric fan (1):
Remove the leg shields,see (LEG SHIELDS
REMOVAL).
Disconnect the electrical connection (2) operating
the electrical fan (1).
Directly supply the electrical fan with a 12 volt
direct current.
chap. 6
2
1
Release 00
2002-09
6-19
Electrical Equipment
Atlantic 500
WATER THERMISTOR CHECK
See (COOLANT THERMISTOR FUNCTION CHECK)
on page 6-14.
FAN RELAY CHECK
To verify that the relay is working:
•
•
•
Remove the seat, see (SEAT REMOVAL).
Supply the two male terminals (85-86) with a 12V
tension.
With a multimeter (set to ohm meter mode) verify
the continuity between the other two terminals (8730).
Correct value with supply to the relay: 0 Ω
Correct value without supply to the relay: ∞ Ω
If the resulting values do not correspond to those
prescribed, replace the relay concerned.
6-20
Release 00
2002-09
chap. 6
Electrical Equipment
Atlantic 500
COOLANT TEMPERATURE AND FUEL LEVEL INDICATORS
WIRING DIAGRAM
43
!
x1000r/min
mp/h
Km/h
EFI
ABS
SET
TRIP
6
B
V
B
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Ar/R
B
B
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
1
Bi/N
W
35
V/N
R/Bi
1
24
B 15A
V/N
C 15A
E 3A
A 15A
D 15A
F
R/Bi
V
Ar/N
G/V
Ar/R
Bi/N
R 20A R/Bi
1
22
R
N
1
8
19
15
Key to wiring diagram
8) Fuel level sensor
15) Water thermistor
19) Battery
22) Main fuses
24) Secondary fuses
35) Key switch
43) Dashboard
chap. 6
Release 00
2002-09
6-21
Electrical Equipment
Atlantic 500
WATER TEMPERATURE
DASHBOARD CHECK
•
•
Disconnect the water thermistor connector and
connect an electrical resistance (from the connector
side) between the orange/red and white/black cables.
Turn the key to ON and verify the indication on the
dashboard.
Connector values:
resistance <60 Ω
resistance 80 Ω
resistance >1090 Ω
bottom scale indication
start of red zone indication ±5°
start of scale indication
WATER THERMISTOR CHECK
See (COOLANT THERMISTOR FUNCTION CHECK)
pages 6-14.
FUEL LEVEL
DASHBOARD CHECK
•
•
Disconnect the pump assembly connector and
connect an electrical resistance (from the connector
side) between the yellow-green and orange-black
cables.
Turn the key to ON and verify the indication on the
dashboard.
Connector values:
resistance 250 Ω 1/2 scale indication ±5°
resistance 3 Ω
full indication
resistance 820 Ω empty indication and indicator lit
VIEWED FROM ”A”
R
FUEL LEVEL SENSOR CHECK
•
•
Disconnect the pump assembly/sensor connector.
Connect an ohm meter to terminals 2 and 3 and
verify the indication at different fuel levels.
Correct value with full tank - less than 16 Ω
Correct value with 8 litres of fuel - 300-400 Ω
Correct value with Ø litres - more than 800 Ω
6-22
Release 00
2002-09
chap. 6
Electrical Equipment
Atlantic 500
LIGHTS AND ACOUSTIC SIGNALS SYSTEM
WIRING DIAGRAM
39
SCROLL
37
PASSING
STOP
G
V/N
G/N
40
B
Gr
G/N
N
Bi
V/N
35
48
G/Gr
G
V/N
R/Bi
G/Gr
V
G/N
B
Gr
G/N
N
Bi
V
V
Gr
1
N
B
N
B
Bi
G
B
Bi
49
N
B
Bi
G
B
Bi
G
B
G
B
G
B
G
G
G
B
B
G
B
G
B
B
R/Bi
50
54
58
31
31
58
54
31
31
1
26
G/Gr
B
6
G
B
B
Ar/N
27
1
24
B
G
B 15A
V/N
C 15A
E 3A V/R
A 15A V/R
D 15A R/Bi
F
V/R
R/Bi
25
V/R
V
N
22
R
R
R
R 30A V/R
R 20A R/Bi
1
19
Key to wiring diagram
19) Battery
22) Main fuses
24) Secondary fuses
25) Top case light
26) Top case switch
27) Number plate light
31) Parking/stop lights bulbs
35) Key switch
37) Right switch
39) Left switch
40) Horn
48) Dipped beam bulbs
49) Full beam bulbs
50) Parking lights bulb
HORN CHECK
Directly supply the horn with 12 V to the two terminal
endings.
If it does not work, activate the special adjuster.
If necessary replace it with a new one.
TOP CASE SWITCH CHECK
With a multimeter in ohm meter mode, verify the
continuity between the two terminals.
Value with the switch free (saddle raised) Ø Ω
Value with the switch pressed (saddle closed) ∞
chap. 6
Release 00
2002-09
6-23
Electrical Equipment
Atlantic 500
DIRECTION INDICATORS AND DISPLAY DATA
WIRING DIAGRAM
43
!
39
SCROLL
x1000r/min
EFI
mp/h
Km/h
PASSING
STOP
ABS
SET
46
B/Bi
M
B/Bi
Bi/G
1
R
B/N
Az
15 16
R/Bi
B/N
Az/Bi
TRIP
12
R
Az
B/N
R/Bi
Az/Bi
Bi/G
5 6 7 8
B/Bi
W
1
R
R
29
Az
30
R
R
R
R
Az
Az
47
Az
Key to wiring diagram
29) Rear right indicator
30) Rear left indicator
39) Left lights switch
43) Dashboard
46) Front right indicator
47) Front left indicator
CONTROLS ON THE LEFT SIDE OF THE
HANDLEBAR
NOTE The electrical components work only with the
ignition switch in position “ ”.
MODE BUTTON (MODE)
Press repeatedly to select the various data visualized
on the Multifuncion LCD display.
HAZARD BUTTON ( )
ACTIVATION
Press to activate the four indicators, at this point it is
possible to turn the ignition switch to position “ “ and
remove the key.
DEACTIVATION
Insert the key in the ignition lock switch and turn to
position “ ”, press the HAZARD button again to
deactivate the system.
NOTE The flashing frequency of the hazard remains
unvaried even with a burnt out bulb.
6-24
Az
1
1
Release 00
2002-09
chap. 6
Electrical Equipment
Atlantic 500
MULTIFUNCTION LCD DISPLAY
Turning the ignition key (1) to position “ ”, all the
segments on the Multifuncion LCD display are activated for a few seconds (in this way working checks
are carried out on the components) and the last
function imposed after the vehicle was stopped is
visualized.
6
7
9
8
10
5
11
AVG VBATT Km/h ml/G Vmax
mph
4
After the first 1,000 Km (625 mi) and then every
6,000 Km (3,750 mi), SERVICE will appear on the
display.
In this case carry out the operations prescribed in
the periodical maintenance programme, see pages
2-3 (PERIODICAL MAINTENANCE PROGRAMME).
"
SERVICE
"
LAP
.
3
The various functions are selected then visualized on
the display by pressing the MODE button (2) on the
controls to the left side of the handlebars.
The segments forming the multifunction LCD display
are as follows:
Chronometer indicator (3), programmed maintenance
due icon (4), average speed icon expressed in mph
(5), average speed (6), battery tension icon (7),
average speed icon expressed in Km/h (8).
(The same icon is used for the consumption function
expressed with the symbol Km//l, consumption
expressed in ml/G (used only for
versions) (9),
maximum speed icon (10), external temperature icon
expressed in degrees Celsius (°C)(11), external
temperature icon expressed in degrees Fahrenheit
(°F) (12), six-figure displays of the values relating to
the functions set and identified by the respective icons
(13).
°C
°F
12
CEV
13
6
2
ZADI
CAUTION
PU
SH
1
By pressing the MODE button, the functions are
obtained in the following sequence:
↓
External temperature in °C
MODE
↓
Maximum speed (Vmax)+km/h or mph
MODE
↓
Average speed AVG (Km/h or mph)
MODE
↓
Battery tension (Vbatt)
MODE
↓
Fuel consumption (km/L or ML/G)
MODE
↓
Chronometer (LAP)
MODE
↓
Km to next maintenance programmed (SERVICE)
MODE
chap. 6
Release 00
2002-09
6-25
Electrical Equipment
Atlantic 500
RESETTING OF AVERAGE SPEED, MAXIMUM
SPEED, FUEL CONSUMPTION AND
CHRONOMETER VALUES
NOTE Cancellation of this information is only
possible if the odometer is visualized to the right of
the digital display.
ABS
/RESET
Keep the TRIP/RESET button (1) pressed for more
than three seconds.
NOTE The function visualized will be cancelled.
1
START/STOP AND CHRONOMETER RESETTING
NOTE Cancellation of this information is only
possible if the odometer is visualized to the right of
the digital display.
START/STOP:
Keep the MODE button (2) pressed for more than
three seconds.
RESETTING:
Keep the TRIP/RESET button (1) pressed for more
than three seconds, only when the chronometer is
stopped.
DIGITAL ODOMETER
NOTE The LCD displays only work with the ignition
switch in position “ ”.
Turning the ignition key (1) to position “ ”, all the
segments are activated on the LCD display for a few
seconds and in this way working checks of the
components can be carried out, after the odometer is
always visible.
The segments forming the LCD display are as follows:
Odometer visualized icon (2), first trip visualized icon
(3), second trip visualized icon (4), 5-figure
visualization of values relating to the selected
functions (5).
ZADI
1
PU
SH
2
5
4
3
ODO TRIP 1 TRIP 2
By pressing the TRIP/RESET button in sequence the
following functions are activated:
1
↓
Odometer (ODO)
TRIP/RESET
↓
First trip (TRIP 1)
TRIP/RESET
↓
Second trip (TRIP 2)
ABS
TRIP/RESET
/ RESET
6-26
Release 00
2002-09
chap. 6
Electrical Equipment
Atlantic 500
DIRECTION INDICATOR AND SPEEDOMETER
WIRING DIAGRAM
43
!
x1000r/min
mp/h
Km/h
EFI
ABS
44
W
SET
TRIP
Ro
M
1
Gr/B
Gr/Bi
B/Ar
Ro
M
1
Gr/B
Gr/Bi
Vi
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
B/Ar
Vi
B/Ar
Gr/Bi
V
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
1
6
42
B
45
Key to wiring diagram
42)
43)
44)
45)
Air temperature thermistor
Dashboard
Speed sensor
Pressure oil sensor
chap. 6
Release 00
2002-09
6-27
Electrical Equipment
Atlantic 500
DASHBOSRD CHECK
•
If the dashboard is in good working order, the red
LED “ ” of the oil pressure should go on with the
ignition switch to the “ ” position.
SENSOR CHECK
•
•
•
1
2
With the ignition switch in position “ ” the red LED
indicator “ ”, relating to engine oil pressure, must
light up.
If the red LED indicator “ ”, does not regularly
light up, verify that the sensor is working.
With a multimeter (scale 100 Ω) verify the
continuity between the pin terminal (1) and the
sensor casing (2)(see diagram).
ENGINE
Correct value with engine off: 0 Ω
Correct value with engine running: ∞ Ω
If the resulting values do not correspond to those
prescribed, check that the engine oil level is correct,
see (ENGINE OIL LEVEL CHECK AND TOPPING UP)
and if necessary replace the sensor.
6-28
Release 00
2002-09
chap. 6
Electrical Equipment
Atlantic 500
SPEEDOMETER
•
•
•
Check the correct coupling of the speed sensor
connector (1).
Check the correct coupling of the dashboard
connectors (2).
Check the distance between the speed sensor (3)
and the front brake disc fixing screws (4).
1
Distance between sensor (3) and screws (4): 1.5 ±
1 mm.
•
Check that all the screws (4) are present.
With engine off and the ignition switch in position “ ”
carry out the following tests:
6
1st Test
• Without disconnecting the speed sensor connector
(1) connect a multimeter and measure the tension
between the grey/blue (Gr/B) and blue/orange (B/
Ar) cables.
2
2
Correct value: > 9 V (c.c.).
2nd Test
• Without disconnecting the speed sensor connector
(1), connect a multimeter and measure the tension
between the grey/white (Gr/Bi) and blue/orange
(B/Ar) cables.
Correct value: > 6 V (c.c.).
3rd Test
• Place the vehicle on the special rear stand
• Carry out the 2nd test.
• Manually turn the front wheel bringing one of the
screws (4) in line with the sensors (3). The
multimeter indication will give zero V for approx.
two seconds, then return to >6 V .
-
-
-
-
1.5 mm
If the 1st test results in an incorrect value, disconnect the sensor (3) and repeat the 1st test; if the
incorrect value persists, the dashboard is defective and must be replaced with one that is known
to work.
If the 1st test results in a correct value and the 2nd
with an incorrect value, the sensor (3) is defective
and must be replaced.
If the 1st and 2nd tests result in a correct value
and the 3rd test with an incorrect value, the sensor
(3) is defective and must be replaced.
If all three tests result in a correct value but the
speed does not appear to the left of the dashboard, the dasboard is defective and must be
replaced with one that is known to work.
chap. 6
Release 00
2002-09
6-29
Electrical Equipment
Atlantic 500
AIR TEMPERATURE SENSOR
To verify that the air temperature sensor works:
•
•
•
Disconnect the two-way connector (1).
Carry out the sensor check in an environment with
controlled temperature of 20 °C (68 °F).
1
Measure the electrical resistance with an ohm
meter (scale 0-20 kΩ) between the connector
terminals (1).
Ω - 12.700 kΩ
Ω
Correct value: 12.200 kΩ
1
If the air temperature sensor works correctly check the
dashboard:
+
•
•
Ω
Apply a resistance equal to 12.4 kΩ between the
sensor terminals (cabling side).
If the dashboard works correctly it should indicate
a temperature of 20 ± 1 °C (68 ± 3 °F).
6-30
Release 00
2002-09
chap. 6
-
Electrical Equipment
Atlantic 500
SWITCHES
Using a pocket multimeter, check the continuity of the
switches by referring to the tables below.
Replace any faulty components.
3
2
5
PASSING
1) HORN BUTTON ( )
Cable
Rs
Gr
MODE
B
1
2) TURN INDICATOR SWITCH (
Cable
Rs
B/Bi
Az
R
4
)
B/N
6
STOP
3) LIGHTS SWITCH (
BEAM BUTTON
(PASSING )
Cable
Rs
G/N
-
) / FLASHING FULL
N
Bi
V/N
PASSING
4) MODE BUTTON (MODE)
Cable
Rs
Ro
V
SCROLL
5) HAZARD BUTTON (
Cable
Rs
B/Bi
)
M
7
6
6) LIGHTS SWITCH (
Cable
Rs
V/N
G
- •)
G/N
8
chap. 6
Release 00
2002-09
6-31
Electrical Equipment
Atlantic 500
BULB REPLACEMENT
WARNING
Before changing a bulb, move the ignition switch
to position “ ” and wait a few minutes, so that
the bulb cools down. Change the bulb wearing
clean gloves or using a clean and dry cloth.
Do not leave fingerprints on the bulb, since these
may cause its overheating and consequent breakage. If you touch the bulb with bare hands, remove any fingerprint with alcohol, in order to
avoid any damage.
DO NOT FORCE THE ELECTRIC CABLES.
HEADLIGHT BULB REPLACEMENT
1
Carefully read BULBS.
The headlight contains:
– Two bulbs for full beam (1).
– One bulb for dipped beam (2).
– One parking light bulb (3).
To change the bulbs, proceed as follows:
• Remove the front hood, see (REMOVAL OF THE
FRONT HOOD).
3
2
LOW/HIGH BEAM BULB
4
CAUTION
To extract the bulb electric connector, do not pull
its electric wires.
•
•
•
Grasp the bulb electric connector (4), pull it and
disconnect it from the bulb (5).
Rotate the bulb socket (6) anticlockwise and
extract it from the reflector.
Extract the bulb (5).
6
For the reassembly:
5
NOTE Insert the bulb (5) in the reflector, ensuring
that the three pins on the bulb coincide with the
respective slots in the bulb casing.
•
•
Position the bulb socket (6) in the reflector and
rotate it clockwise.
Connect the bulb electric connector (4).
6-32
Release 00
2002-09
chap. 6
Electrical Equipment
Atlantic 500
BATTERY
For safety regulations and general information
concerning the battery, see (BATTERY).
For other information, see (ELECTROLYTE LEVEL
CHECK),(BATTERY RECHARGE) and (BATTERY
PROLONGED INACTIVITY).
ACTIVATING THE BATTERY
6
Read through paragraph (BATTERY).
•
•
•
•
Remove the battery cover, see (BATTERY
COVER REMOVAL).
Remove the battery, see (BATTERY REMOVAL).
Check the battery electrolyte level, see (BATTERY
ELECTROLYTE LEVEL CHECK).
Recharge the battery, see (BATTERY RECHARGE).
RETURN UNDER GUARANTEE
Read through paragraph (BATTERY).
The guarantee is considered no longer valid if the
battery shows signs of:
• Damage (casing dented, poles bent, etc.).
• Diffuse formation of sulphate (incorrect activation
and/or use of the battery).
• Insufficient level of electrolytic liquid (to avoid
leakage during transportation it is sufficient to
close the vent with the special cap).
• Missing elements (caps, etc.).
chap. 6
Release 00
2002-09
6-33
Electrical Equipment
Atlantic 500
FULL BEAM BULBS
•
Turn the bulb socket/bulb (8) anticlockwise and
extract it from the parabolic setting.
9
CAUTION
10
To remove the bulb socket/bulb from its connection, take special care not to damage the two
housings (9).
•
•
•
Remove the bulb (10).
Correctly fit a bulb of the same kind.
For reassembly, repeat the operations in reverse
order.
8
PARKING LIGHT BULBS
12
CAUTION
11
To extract the bulb socket, do not pull its electric
wires.
•
•
Working from the front of the vehicle, grasp the
bulb socket (11), pull it and take it out of its seat.
Extract the parking light bulb (12) and replace it
with a new one of the same type.
REPLACING THE REAR LIGHT BULBS
Carefully read BULBS.
1
1
The rear light contains:
– Two bulbs for parking/stop lights (1).
– Two bulbs for rear indicator lights (2).
2
2
To change them:
• Raise the saddle,see (SADDLE UNBLOCKING
AND BLOCKING).
NOTE The following information is only for one
indicator but is valid for both operations.
•
Remove the fixing pommel (3) of the rear lights
assembly of the vehicle.
6-34
Release 00
2002-09
chap. 6
Electrical Equipment
Atlantic 500
CAUTION
During the following operations do not pull or
force the electrical cables.
•
4
Pull out the rear lights assembly (4) first pulling out
the upper part and then distancing it from its
housing.
5
3
CAUTION
Work with caution.
Do not damage the pins and/or their housings.
•
Holding the rear lights assembly by hand, turn it
anticlockwise and remove the bulb socket (5) with
the bulb (6) from the parabolic housing (4).
•
Remove the bulb from the housing.
6
6
NOTE Set the bulb in the bulb socket, ensuring that
the two guiding pins are in line with their respective
slots on the bulb socket.
•
Correctly fit a bulb of the same kind.
NOTE During reassembly, correctly place the protective screen in its housing.
CAUTION
Carefully and gently tighten the pommel (3) in
order to avoid damage to the protective screen.
FRONT INDICATOR LIGHTS BULB
REPLACEMENT
Carefully read BULBS.
To change the bulbs:
• Remove the front hood, see (FRONT HOOD
REMOVAL). As an alternative, it is also possible to
remove the box covers to gain access to the bulbs
(see DASHBOARD REMOVAL).
2
1
CAUTION
Proceed with care.
Do not damage the tangs and/or their seatsstro.
For the LEFT indicator:
• Working from the front of the vehicle, turn the
support (1) clockwise with the bulb (2) and remove
both from the housing.
• Gently press the bulb (2) and turn it anticlockwise.
• Extract the bulb from its seat.
NOTE Insert the bulb in the bulb socket, making the
two bulb pins coincide with the relevant guides on the
socket.
• Correctly fit a bulb of the same kind.
• For reassembly repeat the operations in reverse
order.
For the RIGHT indicator:
• Pull the secondary fuse box (3) from its housing in
order to have sufficient space for dismantling
operations.
• Continue as described for the LEFT indicator.
chap. 6
Release 00
3
2002-09
6-35
Electrical Equipment
Atlantic 500
NUMBER PLATE LIGHT REPLACEMENT
Carefully read BULBS.
2
To change the bulbs:
CAUTION
Do not pull the electrical cables when removing
the bulb socket.
•
•
Grasp the bulb socket (1), pull and remove it from
its housing.
Pull out and replace the bulb (2) with one of the
same kind.
1
HELMET COMPARTMENT LIGHT REPLACEMENT
Carefully read BULBS.
2
To change the bulbs:
• Lift the saddle, see (SADDLE UNBLOCKING/
BLOCKING).
• Loosen and remove the screw (1) fixing the glass
to the battery cover.
• Remove the glass (2) by pulling downwards.
3
1
4
CAUTION
Do not pull the electrical cables when removing
the bulb socket.
•
•
Grasp the bulb socket (3), pull and remove it from
its housing.
Pull out and replace the bulb (4) with one of the
same kind.
THIRD STOP LIGHTS REPLACEMENT
2
Carefully read BULBS.
To change the bulbs:
• Lift the saddle, see (UNBLOCKING/BLOCKING
THE SADDLE).
• Loosen and remove the two fixing screws (1) of
the backrest.
CAUTION
When removing the backrest, proceed with caution in order to avoid breaking the coupling
prongs.
•
1
Remove the backrest (2) by pulling upwards.
6-36
Release 00
2002-09
chap. 6
Electrical Equipment
•
•
•
Atlantic 500
Loosen and remove the two fixing screws (3) of
the protective screen (4) of the third stop light.
Pull out the all-glass bulbs (5) from their housing.
Correctly fit a bulb of the same kind.
3
NOTE During reassembly, correctly set the
5
protective screen in its housing.
6
CAUTION
Carefully and gently tighten the screw (3) in order
to avoid damaging the protective screen.
4
VERTICAL BEAM ADJUSTMENT
•
•
To quickly check the alignment of the headlight
beam, place the vehicle on level ground, 10
metres from a vertical wall.
Turn on the low beam, sit on the vehicle and
check that the top of the lighted area on the wall is
slightly lower than the projection of the headlight
axis (approximately 9/10 of the overall height).
To adjust the headlight beam:
•
•
•
Use the special handle (1) from the front of the
vehicle.
Turning it CLOCKWISE, the beam is raised.
Turning it ANTICLOCKWISE, the beam is
lowered.
1
chap. 6
Release 00
2002-09
6-37
Electrical Equipment
Atlantic 500
HORIZONTAL BEAM ADJUSTMENT
•
Remove the internal front shield, see (INTERNAL
FRONT SHIELD REMOVAL).
To carry out the beam adjustment:
• Use the special handle (as indicated on the
diagram) from the front of the vehicle.
• Turn CLOCKWISE and the beam will move to the
RIGHT (with respect to the direction faced).
• Turn ANTICLOCKWISE and the beam will move
to the LEFT (with respect to the direction faced).
REPLACING THE FUSES
Carefully read (MAINTENANCE).
CAUTION
Do not repair faulty fuses.
Never use fuses different from the recommended
ones.
The use of unsuitable fuses may damage the
electric system or, in case of short circuit, may
even cause a fire.
1
NOTE If a fuse blows frequently, there probably is a
short circuit or an overload in the electric system.
•
•
If an electric component does not work or works
irregularly, or if the engine fails to start, it is
necessary to check the fuses.
Check the 3 A and the 15 A fuses first and then
the 20-30 A fuse.
To carry out the checking:
•
•
•
•
Remove the battery cover, see (BATTERY
COVER REMOVAL) or remove the front hood, see
(FRONT HOOD REMOVAL).
Extract the fuses one by one and check if the
filament (1) is broken.
Before replacing a fuse, try to find out the cause of
the trouble, if possible.
Then replace the damaged fuse with a new one
having the same amperage.
2
3
4
5
6
9
NOTE If you use one of the spare fuses, put a new
fuse in the appropriate seat.
•
Replace the battery cover, see (BATTERY
COVER REMOVAL) or replace the front hood, see
(FRONT HOOD REMOVAL).
6-38
Release 00
2002-09
7
8
chap. 6
Electrical Equipment
Atlantic 500
SECONDARY FUSE LAYOUT
(FRONT HOOD)
– 15 A (2) fuse
From voltage regulator to: injection, stop/starting
lights logistics (Housing A on the wire diagram).
– 15 A (3) fuse
From the ignition switch to: engine kill logistics,
stop lights (Housing B on the wire diagram).
– 15 A (4) fuse
From the ignition switch to: lights, horn,
dashboard, fan relay, radio power supply
(Housing C on the wire diagram).
– 15 A (5) fuse
From the main fuse to the power socket in the
glove compartment .
– 3 A (6) fuse
From the voltage regulator to permanent supply
of the ECU control unit (Housing E on the wire
diagram).
– 15 A (7) fuse
Spare.
– 3 A (8) fuse
Spare.
– Free (9)
10
11
12
6
MAIN FUSE LAYOUT
(BATTERY COMPARTMENT)
– 20 A (10) fuse
From the battery to: ignition switch, fuse (2),
helmet compartment light, cooling fan, permanent
supply to the dashboard.
– 30 A (11) fuse
From the battery to: voltage regulator, fuse (3),
fuse (5).
– 30 A (12) fuse
Spare.
chap. 6
Release 00
2002-09
6-39
Electrical Equipment
Atlantic 500
ELECTRICAL COMPONENTS LAYOUT
43
33
39
25
3
13
47
56
24
31
28
30
51
53
49
27
50
55
23
40
16
KEY
3) Stepper motor
4) Coil
5) Spark plug
6) Fuel injector
11) Side stand switch
13) Accelerator sensor
14) Engine air thermistor
15) Dashboard / engine water thermistor
16) Fan
23) Power socket
24) Secondary fuses
25) Top case light
27) Number plate light
6-40
6
Release 00
11
4
5
14
28) Radio power supply
30) Rear left indicator
31) Parking/stop lights
33) Rear stop light switch
39) Left indicator lights
40) Horn
43) Dashboard
47) Front left indicator
49) Full beam bulbs
50) Parking lights bulb
51) Headlight
53) Left tail lamp
55) Stop lights relay
56) 3 stop light bulbs
2002-09
chap. 6
15
Electrical Equipment
Atlantic 500
ELECTRICAL COMPONENTS LAYOUT
20
2
22
35
34
37
19
38
36
32
9
31
29
10
17
48
26
42
45
6
46
21
18
KEY
2) Revolutions sensor
7) Fuel pump
8) Fuel level feeler
9) Main injection relay (with diode)
10) Secondary injection relay
17) Voltage regulator
18) Flywheel
19) Battery
20) Starting relay
21) Starting motor
22) Main fuses
26) Compartment switch
29) Rear right indicator
chap. 6
54
7
8
52
44
31) Parking/stop lights
32) Right tail lamp
34) Front stop light switch
35) Key switch
36) Drop sensor
37) Right switch
38) Fan relay
42) Dashboard air temperature thermistor
44) Speed sensor
45) Oil pressure sensor
46) Front right indicator
48) Dipped beam bulb
52) E.C.U. control unit
54) Diagnostics socket
Release 00
2002-09
6-41
51
50
47
G
B
B
Az
G
B
R
N
B
Bi
G
Az
SECONDARY FUSES:
B
Bi
B
Bi
N
B
R
B
1
52
R
N
B
Bi
G
Az
A - INJECTION, STARTING.
B - ENGINE KILL, STOPLIGHT.
C - LIGHT, CLAXON, DASHBOARD, FAN RELAY.
D - POWER SOCKET.
E - E.C.U. SYSTEM.
F - FREE.
49
48
46
M/Bi
1
V/G
2
Az/R
3
Ar
4
R/B
5
Vi
6
B
7
Ro/G
8
M
9
R
10
11 M/G
B/N
12
Gr/R
13
Az
14
Az/V
15
Ro/G
16
Ar/N
17
18 Ro/N
Vi/N
19
Ar/Bi
20
G
21
Gr
22
23 N
24 Ro
25 Gr/N
26
N
1
1
2
1
Az
Ro
G
Vi
3
4
5
1
6
Az/V
TRIP
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Gr/Bi
R/M
Gr/R
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Gr/B
Ar/R
M
B
7
P
B
R/M
Ar/N
G/V
SET
8
1
54
R
M
W
B
B
44
B
Ar/N
B
G/V
B/N
R/Bi
Az/Bi
Bi/G
R/Bi
R/Bi
Az/R
B/Bi
Vi
M/V
R
Az
Ar/Bi
R/M
ABS
9
G/B
1
57
10
1
42
11
1
R/M
Ro/G
V/G
12
40
1
STOP
1
39
13
14
1
15
33
V/G
R/N
B/G
Gr/N
PASSING
V
Gr
B
Vi
E.C.U. CONTROL UNIT
B/Ar
Gr/Bi
V
Gr/B
Gr/Bi
B/Ar
N
38
16
1
1
37
V/G
G/R
45
N
V
B/Ar
Ar
Bi/N
Ro
G/Gr
Bi
N
M/N
R/N
Gr/N
Ar/V
85
86
87
30
Gr/N
R/B
R/M
Ar/V
1
2
5
3
G
V/N
R/N
G/N
B/G
G/R
SCROLL
Gr
M/Bi
M/G
R
B/N
Az
B
Gr
G/N
N
Bi
V/N
R/Bi
B/N
Az/Bi
B
Gr
G/N
N
Bi
V
Gr
Ro/N
B/Bi
M
Ro
V
B/Bi
Bi/G
Ar
V
Gr
Ar
Ar/R
Bi/N
17
34
Gr/N
V/G
1
R/Gr
R/Gr
Gr/N
EFI
B
M/N
M/V
N
V
M
1
36
18
28
R/Gr
V
Ar/N
Ar/V
Ar
24
B 15A
C 15A
E 3A
A 15A
D 15A
F
23
V
30
87
85
86
G/N
R/Bi
Vi/N
V
B
G/N
B
G/N
Bi/N
N
Ro/G
Gr
G
G
G
G/Gr
V
R/N
N
N
V/R
V/R
V
V
R/Bi
R/Bi
B
!
B
G/N
G
G
G
G
G
G
V/N
V/N
V/R
V/R
R/Bi
1
V/R
19
R
35
22
1
R/Bi
B
Ar/N
mp/h
Km/h
30
85
86
87
1
25
1
26
55
20
R
R
x1000r/min
N
N
G/Gr
G
V/N
R/Bi
V/R
R/Bi
R 30A V/R
R 20A R/Bi
R
R
2002-09
B
G
R/N
B/G
B
V/G
G/R
B
Release 00
R/Bi
B/Bi
21
M
G
B
G
V/G
B
Az
G
V/G
B
Az
G/Gr
B
R
V/G
G
B
1
1
R
V/G
G
B
V/G
B
1
37
27
B
Az
G
V/G
B
31
54
58
31
58
54
56
V/G
G
B
R
B
Gr/N
V/G
34
30
29
MODIFICATION FOR ASD VERSION
R/Gr
6-42
V/G
G/R
V/N
V/N
V/N
R/N
43
31
31
53
32
Electrical Equipment
Atlantic 500
WIRING DIAGRAM 500 C.C. ATLANTIC SCOOTER
chap. 6
Ro
M
Electrical Equipment
WIRING DIAGRAM KEY
1) Multiple connectors
2) Revolutions sensor
3) Stepper motor
4) Coil
5) Spark plug
6) Fuel injector
7) Fuel pump
8) Fuel level feeler
9) Main injection relay (with diode)
10) Secondary injection relay
11) Side stand switch
12) Lambda feeler (optional)
13) Accelerator sensor
14) Engine air thermistor
15) Dashboard/engine water thermistor
16) Fan
17) Voltage regulator
18) Flywheel
19) Battery
20) Starting relay
21) Starting motor
22) Main fuses
23) Power socket
24) Secondary fuses
25) Top case light
26) Compartment light switch
27) Number plate light
28) Radio power supply
29) Rear right indicator
30) Rear left indicator
31) Parking/stop lights
32) Right tail lamp
33) Rear stop light switch
34) Front stop light switch
35) Key switch
36) Drop sensor
37) Right switch
38) Fan relay
39) Left switch
40) Horn
42) Dashboard air T thermistor
43) Dashboard
44) Speed sensor
45) Oil pressure sensor
46) Front right indicator
47) Front left indicator
48) Dipped beam bulb
49) Full beam bulbs
50) Parking lights bulb
51) Headlight
52) E.C.U. control unit
53) Left tail lamp
54) Diagnostics power socket
55) Stop lights relay
56) Third stop light bulbs
57) Handbrake switch (optional)
chap. 6
Atlantic 500
CABLE COLOURS
Ar orange
Az light blue
B
blue
Bi white
G yellow
Gr gray
M brown
N
black
R
red
V
green
Vi violet
Ro pink
6
Release 00
2002-09
6-43
Electrical Equipment
6-44
Atlantic 500
Release 00
2002-09
chap. 6
Cycle parts
Atlantic 500
7
Cycle parts
chap. 7
Release 00
2002-09
7-1
Cycle parts
Atlantic 500
BODYWORK
PASSENGER FOOTREST REMOVAL
1
1
Place the vehicle on the central stand.
CAUTION
Work with care.
Unscrew and remove the three screws (1).
Remove the passenger footrest (2).
2
LOWER PROTECTION COVER REMOVAL
3
Place the vehicle on the central stand.
CAUTION
Work with care. Do not damage the tongue and/or
the relative seats. Handle the painted components
with care. Do not drag them or ruin them.
Unscrew and remove the four screws (3) on the r.h.
side, and the four screws on the l.h. side.
Remove the breather pipe from the expansion tank.
5
Unscrew and remove the screw (4) placed on the
leading edge, behind the front wheel.
Remove the lower protection cover (5), supporting it to
prevent it from dropping.
4
5
UNLOCKING/LOCKING THE SEAT
2
Position the vehicle on the central stand.
Insert the key (1) into the ignition switch (2).
Press and rotate the ignition key (1) in an anti-clockwise direction.
Via the pneumatic piston, the seat (3) remains in a
raised position and the under-seat compartment is
illuminated.
To lock the seat, lower it and press it (without forcing
it), making the lock click.
ZADI
3
PU
SH
1
WARNING
Before riding again, make sure that the seat is
correctly locked.
7-2
Release 00
2002-09
chap. 7
Cycle parts
Atlantic 500
SEAT REMOVAL
4
Place the vehicle on the central stand.
Lift up the seat (4) (see UNLOCKING/LOCKING THE
SEAT).
CAUTION
Work with care.
Utilising a suitable pincer, unclip the clip (5).
6
5
7
CAUTION
Prop up the seat do make sure it does not fall
unexpectedly.
Remove the pin (6).
Unscrew and remove the four nuts (7).
Remove the seat (4).
7
CENTRAL TUNNEL REMOVAL
Place the vehicle on the central stand.
Remove the seat (see SEAT REMOVAL).
Remove the right and left inspection covers (see
RIGHT AND LEFT INSPECTION COVER REMOVAL).
Remove the legshield (see LEGSHIELD REMOVAL).
1
CAUTION
Work with care. Do not damage the tongue and/or
the relative seats. Handle the painted components
with care. Do not drag them or ruin them.
3
Unscrew and remove the two screws (1) on the right
and left side.
Unscrew and remove the screw (2) on the right and
left side.
Remove the central tunnel (3).
2
3
chap. 7
Release 00
2002-09
7-3
Cycle parts
Atlantic 500
LEFT AND RIGHT HAND INSPECTION COVER
REMOVAL
1
2
Place the vehicle on the central stand.
Remove the left and right hand rubber mats (1) by lifting them up with the hands.
Unscrew and remove the screw (2).
CAUTION
Work with care.
Do not damage the tabs (3) and/or the relative
seats. Handle the painted and plastic components
with care. Do not drag them or ruin them.
Utilising a screwdriver, pull up the lower part of the
inspection cover (4) until it slips out from its seat.
3
3
CAUTION
When reassembling, correctly insert the tabs into
their relative seats
4
LEGSHIELD REMOVAL
1
Place the vehicle in the central stand.
CAUTION
Work with care.
Do not damage the tongue and/or the relative
seats. Handle the painted components with care.
Do not drag them or ruin them.
Remove the rubber foot mat by lifting it with the
hands.
Unscrew and remove the three screws (1).
Open the door of the document compartment (see
DOCUMENT COMPARTMENT).
Unscrew and remove the three screws (2).
CAUTION
Work with care.
Do not damage the plastic finish.
2
7-4
Release 00
2002-09
chap. 7
Cycle parts
Atlantic 500
Utilising a flat-bladed screwdriver (3), lever up the
speaker cover (4) to free it from its seat, as indicated
in the figure.
Remove the speaker cover (4).
3
4
Unscrew and remove the two screws (5).
5
7
CAUTION
Work with care. Do not damage the tongue and/or
the relative seats. Handle the painted components
with care. Do not drag them or ruin them.
3
Utilising a flat-bladed screwdriver (3), lever up the
edge of the legshield in such a way that it frees itself
from its seat.
Once the legshield is freed from its seat, remove it
slightly to disconnect the electrical connection (6) from
the 180W electrical socket situated inside the document compartment.
6
chap. 7
Release 00
2002-09
7-5
Cycle parts
Atlantic 500
Pull the tabs (7) towards the cable (9), in such a way
that the cable head (8) is freed by lifting it up. Pull the
cable (9) in the direction indicated by the arrow to free
the legshield from the document compartment closure.
Remove the legshield (10).
7
8
9
10
DOCUMENT COMPARTMENT
1
Thanks to the utilisation of the document compartment
it is not necessary to carry cumbersome objects
around with you every time you park the vehicle.
Insert the key (1) into the ignition switch (2).
Press and rotate the key in an anti-clockwise direction.
The door of the document compartment (3) opens
automatically.
Inside the document compartment there is a 12V
socket (4).
The socket can be utilised for as an electrical feed for
items with an output of not more than 180W (mobile
phones, inspection lamp, etc.).
2
4
3
CAUTION
The prolonged use of the electrical socket without
the engine switched on can cause a partial discharge of the battery.
FRONT MUDGUARD REMOVAL
6
Place the vehicle on the central stand.
CAUTION
Work with care. Do not damage the tongue and/or
the relative seats. Handle the painted components
with care. Do not drag them or ruin them.
5
Unscrew and remove the screw (7).
Unscrew and remove the two screws (5).
Remove the front mudguard (6) by releasing it from
the front part of the vehicle.
7-6
Release 00
7
2002-09
chap. 7
Cycle parts
Atlantic 500
PASSENGER HANDLE-GRIP REMOVAL
8
Place the machine on the central stand.
CAUTION
9
Work with care. Do not damage the tongue and/or
the relative seats. Handle the painted components
with care. Do not drag them or ruin them.
Lift up the seat (see UNLOCKING/LOCKING THE
SEAT).
Utilising a small flat head screwdriver, lever up the two
rubber plugs (8).
Unscrew and remove the two screws (9).
Remove the passenger handle-grip (10) by rotating it
towards the vehicle.
10
10
COMPLETE SIDE PANEL REMOVAL
4
Remove the inspection covers (see RIGHT AND LEFT
HAND INSPECTION COVER REMOVAL).
Remove the passenger footrests (see PASSENGER
FOOTREST REMOVAL).
Lift up the seat (see UNLOCKING/LOCKING OF THE
SEAT).
Place the vehicle on the central stand.
Unscrew and remove the three screws (1).
Unscrew and remove the screw (2).
1
2
7
7
From inside the crash helmet compartment, slacken
and remove the fixing knob (3) of the light assembly
(4).
Slightly lift up the rear light assembly (4) from the side
panel and disconnect the electrical connection (5).
Remove the rear light assembly (4).
5
3
Unscrew and remove the three screws (6).
Lower the side stand (only for the left side).
Remove screw (A) from the number plate holder .
Rotating away from the vehicle, remove the cover (7)
complete with the chromed strip.
6
A
7
▲
▲
chap. 7
Release 00
2002-09
7-7
Cycle parts
Atlantic 500
REMOVAL OF THE CHROMED STRIP FROM THE
SIDE PANELS
Remove the complete side panel (see COMPLETE
SIDE PANEL REMOVAL).
1
CAUTION
Work with care. Do not damage the tongue and/or
the relative seats. Handle the painted components
with care. Do not drag them or ruin them.
Unscrew and remove the screw (1) situated inside the
side panel.
Remove the chromed strip by slightly arcing it in the
central part.
SIDE PANEL SEPARATION
3
Remove the complete side panels (see COMPLETE
SIDE PANEL REMOVAL).
Remove the chromed strip on the side panels (see
REMOVAL OF THE CHROMED STRIP FROM THE
SIDE PANELS).
2
CAUTION
Work with care. Do not damage the tongue and/or
the relative seats. Handle the painted components
with care. Do not drag them or ruin them.
4
Unscrew and remove the screw (2) situated under the
chromed strip.
Separate the two screws of the side panels (3) and
(4), sliding them against one another but also paying
attention to not damage the tabs.
7-8
Release 00
2002-09
chap. 7
Cycle parts
Atlantic 500
1
FOOT PLATFORM REMOVAL
Place the vehicle on the central stand.
Remove the rubber mats (1) by lifting them by hand.
Remove the cover to gain access to the spark plug
(A).
A
CAUTION
Work with care. Do not damage the tongue and/or
the relative seats. Handle the painted components
with care. Do not drag them or ruin them.
Unscrew and remove the seven screws (2).
Remove the foot platform (3).
2
3
2
7
SPRAY GUARD REMOVAL
Place the vehicle on the central stand.
CAUTION
Work with care. Do not damage the tongue and/or
the relative seats. Handle the painted components
with care. Do not drag them or ruin them.
6
4
Remove the front mudguard (see FRONT MUDGUARD REMOVAL).
Remove the front wheel (see FRONT WHEEL REMOVAL).
Unscrew and remove the three screws (4) (on the
right and left side of the vehicle).
Unscrew and remove the screw (5).
Remove the spray guard (6) by sliding it out from
underneath.
6
5
chap. 7
Release 00
2002-09
7-9
Cycle parts
Atlantic 500
FRONT SHIELD REMOVAL
Remove the spray guard (see SPRAY GUARD REMOVAL).
Remove the legshield (see LEGSHIELD REMOVAL).
3
CAUTION
1
Work with care. Do not damage the tongue and/or
the relative seats. Handle the painted components
with care. Do not drag them or ruin them.
1
2
Unscrew and remove the three screws (1) (three on
the right and three on the left).
Free the front shield (2) from its supports by acting on
the tabs (3) via the utilisation of a flat head screwdriver.
Remove the front shield (2), sliding it out from the front
part of the vehicle.
PASSENGER BACKREST REMOVAL
2
Lift up the seat (see UNLOCKING/LOCKING OF THE
SEAT).
Slacken and remove the two fixing screws (1) of the
backrest.
CAUTION
During the backrest removal, proceed with care so
as not to break the engagement teeth.
1
Remove the backrest (2) by pulling it upwards.
PLASTIC BACKREST REMOVAL
Remove the passenger backrest (see PASSENGER
BACKREST REMOVAL).
Unscrew and remove the two screws (1).
Remove the cover (2) of the seat closure.
7-10
Release 00
1
2
2002-09
chap. 7
Cycle parts
Atlantic 500
Unscrew and remove the seven screws (3).
Disconnect the electrical connection (4).
Remove the support arc (5).
7
3
4
5
3
3
3
Disconnec the electrical connection from the bulbs (6)
and the third stoplight.
Lift up and remove the plastic part (7) of the backrest.
7
6
7
REAR MUDGUARD REMOVAL
2
Place the vehicle on the central stand.
CAUTION
Work with care. Do not damage the tongue and/or
the relative seats. Handle the painted components
with care. Do not drag them or ruin them.
1
Unscrew and remove the two screws (1).
Remove the number plate light cover.
Remove the plastic cover by pulling it (2).
Unscrew and remove the four screws (3).
Support and slightly remove the rear mudguard (4).
4
3
3
chap. 7
Release 00
3
2002-09
7-11
Cycle parts
Atlantic 500
Holding the rear mudguard in the hand, disconnect
the number plate light bulb (5), slide out the battery
overflow tube (6) from the guide clip (7).
Remove the rear mudguard (4).
5
4
6
7
TAIL UNIT REMOVAL
1
Remove the plastic backrest (see PLASTIC
BACKREST REMOVAL).
Remove the rear mudguard (see REAR MUDGUARD
REMOVAL).
Remove the rear light assembly (see COMPLETE
SIDE PANEL REMOVAL).
Unscrew and remove the three screws (1).
3
Unscrew and remove the three screws (2), taking care
to recover the washers and ferrules.
Remove the tail unit by sliding out from the rear of the
vehicle (3).
2
3
LOWER COVER REMOVAL
4
Place the vehicle on the central stand.
CAUTION
Work with care. Do not damage the tongue and/or
the relative seats. Handle the painted components
with care. Do not drag them or ruin them.
5
Unscrew and remove the two screws (4).
Remove the lower cover (5).
7-12
Release 00
2002-09
chap. 7
Cycle parts
Atlantic 500
FOOTREST SUPPORT AND LOWER SPRAY
GUARD REMOVAL
Remove the legshield (see LEGSHIELD REMOVAL).
Remove the central tunnel (see CENTRAL TUNNEL
REMOVAL).
Unscrew and remove the two screws (1).
Remove the chromed protection tube (2).
2
1
Unscrew and remove the five screws (3).
Remove the footrest support. (4).
4
3
7
Support the lower spray guard (5).
Disconnect the overflow tube (6) of the coolant tank.
Remove the lower spray guard (5).
6
5
chap. 7
Release 00
2002-09
7-13
Cycle parts
Atlantic 500
FRONT PANEL REMOVAL
1
1
Place the vehicle on the central stand.
Unscrew and remove the two screws (1).
CAUTION
Work with care. Do not damage the tongue and/or
the relative seats. Handle the painted components
with care. Do not drag them or ruin them.
ABS
Unscrew and remove the two screws (2).
CAUTION
During the removal, take care to not drop the clips
attached to the engagement tabs.
Slightly widen the tabs of the front panel as indicated
by the arrow “A” in such a way that the engagement
tabs are freed from the windshield.
Slightly lift up the lower part of the front panel, as
indicated by arrow “B”.
Remove the front panel (3) by pulling it with caution.
3
2
CAUTION
When reassembling, correctly insert the engagement tabs into their appropriate seats with their
relative clips.
UPPER HANDLEBAR COVER REMOVAL
2
Remove the legshield (see LEGSHIELD REMOVAL).
Unscrew and remove the screw (1).
Lift up and remove the cover (2).
1
Unscrew and remove the five screws (3).
3
5
7-14
Release 00
2002-09
chap. 7
Cycle parts
Atlantic 500
Unscrew and remove the two screws (4) on the right
and left side of the vehicle.
Remove the upper handlebar cover (5).
4
4
LOWER HANDLEBAR COVER REMOVAL
2
2
Remove the upper handlebar cover (see UPPER
HANDLEBAR REMOVAL).
Unscrew and remove the three screws (1).
Separate the plastic parts (2) by pulling them outwards.
1
1
7
COMPLETE INSTRUMENT PANEL REMOVAL
Place the vehicle on the central stand.
CAUTION
2
Work with care. Do not damage the tongue and/or
the relative seats. Handle the painted components
with care. Do not drag them or ruin them.
1
Utilising a flat head screwdriver (1), lever up the
speaker cover (2) to free it from its seat (as indicated
in the figure).
Remove the speaker cover (2).
Unscrew and remove the two screws (3).
3
chap. 7
Release 00
2002-09
7-15
Cycle parts
Atlantic 500
Remove the front panel (see FRONT PANEL REMOVAL).
Remove the windshield (see WINDSHIELD REMOVAL).
Unscrew and remove the screw (4).
4
Lift up the complete instrument panel (5) and disconnect the electrical connections (6) directly from the
instrument panel.
Remove the complete instrument panel (5).
5
6
WINDSHIELD REMOVAL
2
Carefully read (MAINTENANCE).
Place the vehicle on the central stand.
Remove the front panel (see FRONT PANEL REMOVAL).
Slacken and remove the six fixing screws (1) of the
front panel.
Remove the front panel (2).
1
1
INSTRUMENT PANEL REMOVAL
1
1
Remove the complete instrument panel (see INSTRUMENT PANEL REMOVAL).
Unscrew and remove the four screws (1).
Remove the instrument panel (2).
2
1
7-16
Release 00
2002-09
chap. 7
Cycle parts
Atlantic 500
COMPLETE LIGHTING ASSEMBLY REMOVAL
Remove the hood, (see WINDSHIELD REMOVAL).
Remove the front spray guard (see FRONT SPRAY
GUARD REMOVAL).
Remove the front panel (see FRONT PANEL REMOVAL).
Remove the complete instrument panel (see INSTRUMENT PANEL REMOVAL).
Unscrew and remove the screw (1).
1
6
4
Unscrew and remove the two screws (2) and recover
the relative self-locking nut.
Unscrew and remove the screw (3).
Unscrew the cap of the coolant tank (4).
Unloose the two screws of the lower bow (above the
fork).
6
2
2
3
7
Disconnect the electrical connection (5).
Remove the complete lighting assembly (6).
5
chap. 7
Release 00
2002-09
7-17
Cycle parts
Atlantic 500
CRASH HELMET COMPARTMENT REMOVAL
Remove the seat (see SEAT REMOVAL).
Remove the central tunnel (see CENTRAL TUNNEL
REMOVAL).
Remove the left and right hand side panels (see
COMPLETE SIDE PANEL REMOVAL).
Unscrew and remove the two screws (1) and recover
the relative washers.
(Carry out this operation also on the right hand side)
1
Unscrew and remove the two fixing screws (2) of the
seat lock (3) from the crash helmet compartment and
free the lock from the crash helmet compartment.
3
2
Slide out the relay (4) by pulling it upwards.
4
Remove the battery cover (see BATTERY COVER
REMOVAL).
Disconnect the electrical connections (5) of the
battery.
Remove the battery (see BATTERY REMOVAL).
5
5
5
7-18
Release 00
2002-09
chap. 7
Cycle parts
Atlantic 500
Slide the starter relay (6) out of its seat inside the
battery compartment.
Support it by hand and slide off the rubber protection
cover (7).
Unscrew and remove the nut (8).
7
8
6
Slide out from the rear, the wiring that comes out of
the crash helmet compartment.
Slide out the starter relay lead (9).
Slide out the battery lead (10).
Slide out the earth lead (11).
Slide out the fuse lead (12).
10
12
11
9
7
Disconnect the battery breather tube (13) from the clip
(14).
13
14
Remove the clip (15) and slide out the pin (16).
Remove the seat hinge (17).
17
16
15
chap. 7
Release 00
2002-09
7-19
Cycle parts
Atlantic 500
Unscrew and remove the two screws (18).
18
Unscrew and remove the four screws (19) of the
carburettor cover (20).
Remove the carburettor cover (20).
19
20
Slacken the bands (22) via the screw (21) and slide
out the fuel breather tube (23) by pulling it outwards.
23
21
22
Unscrew and remove the six screws (24) from the
filter box (25).
24
25
24
7-20
Release 00
2002-09
chap. 7
Cycle parts
Atlantic 500
NOTE Make sure that you have a new band before
substituting the old one.
26
Remove the plastic band (26) and slide out the tube
(27).
Remove the engine cover (25) by lifting it upwards.
Disconnect the electrical connections (28) of the crash
helmet compartment light switch.
Remove the crash helmet compartment (29) by lifting
up the front part and moving the complete unit forwards.
27
29
28
7
chap. 7
Release 00
2002-09
7-21
Cycle parts
Atlantic 500
FRONT WHEEL
6
2
4
5
11
7
3
10
8
9
12
1
KEY
1) Axle
2) Odometer sensor
3) r.h. outer spacer
4) r.h. oil seal
5) r.h. bearing
6) Wheel
7) Inner spacer
8) l.h. bearing
9) l.h. oil seal
10) l.h. brake disc
11) r.h. brake disc
12) l.h. outer spacer
7-22
Release 00
2002-09
chap. 7
Cycle parts
Atlantic 500
REMOVING THE FRONT WHEEL
5
Read through the paragraph (PRECAUTIONS AND
GENERAL INFORMATION).
1
CAUTION
When removing/refitting the parts, take care not to
damage the brake line, the disc and the pads.
2
Put the vehicle on the central stand.
1
WARNING
Place a suitable support under the vehicle so that
there is room for the front wheel to move and the
vehicle does not topple over.
NOTE Perform the following operation also on the
r.h. side of the vehicle.
Remove the two screws (1).
Carefully release the brake caliper (2).
Unloose screw (3).
3
NOTE To ensure proper refitting, carefully check the
positions of the parts, the washers and the spacer.
4
7
Unscrew the wheel pin (4).
Support the front wheel (5) and manually pull out axle
(4).
Remove wheel (5).
Keep the right and left spacers.
WARNING
Do not pull the front brake lever after removing
the wheel as the caliper piston may come out of
its seat and cause a leakage of brake fluid.
For instructions on how to refit the wheel, (see REFITTING).
chap. 7
Release 00
2002-09
7-23
Cycle parts
Atlantic 500
REPLACING THE BEARINGS
Read through the paragraph (PRECAUTIONS AND
GENERAL INFORMATION).
1
CAUTION
2
The bearings must be checked and if necessary
replaced every time they are removed.
Clean both sides of the hub with a rag.
Removal
3
Working on the left side of the vehicle:
Insert a drift (with no point) into the wheel hub and act
on the inner race of right-hand bearing (1), taking care
to shift the strike points (by 90°) so as not to offset the
bearing.
Extract right-hand bearing (1).
Extract spacer (2).
Working on the right side of the vehicle:
CAUTION
Maintain the drift perpendicular to the bearing (on
the same axis as the axle) to avoid offsetting and
damaging the latter.
Insert a bumper with diameter of 15 mm (0.59 in) into
the wheel hub and lean it against the ring inside the
left bearing (3).
Drive out the bearing by repeatedly hitting the drift
with moderate force with a plastic mallet.
Refitting
Working on the right side of the vehicle:
Rest the bearing on the wheel hub.
CAUTION
Maintain the drift perpendicular to the bearing (on
the same axis as the axle) to avoid offsetting and
damaging the bearing.
Lean a bumper with diameter of 31 mm (1.22 in)
against the bearing outer diameter.
Fully insert right-hand bearing (1) by repeatedly hitting
the drift with moderate force with a plastic mallet.
Fit spacer (2).
Working on the left side of the vehicle:
Repeat the first three steps for left-hand bearing (3).
WARNING
Check the bearings centering to the wheel hub.
7-24
Release 00
2002-09
chap. 7
Cycle parts
Atlantic 500
CHECK
CAUTION
Check the condition of all components, and in
particular of those listed below.
1
Bearings
Manually rotate inner race (1), making sure it turns
smoothly without any sticking and/or noise.
Also check that there is no axial play.
Replace any bearings showing the above defects.
CAUTION
Grease the balls (or rollers) at the sides of each
bearing (see LUBRICANT CHART).
The operation is unnecessary if the bearings are
of the self-lubricating type.
Axle
Check the pin runout using a dial gauge.
If the runout exceeds the maximum allowed limit,
replace the pin.
Maximum runout: 0.25 mm (0.0098 in)
CAUTION
Lubricate the pin (only the area in contact with the
bearings) see (TABLE OF LUBRICANTS).
7
Wheel rim
Using a dial gauge, check that the radial and axial
runout of the wheel rim does not exceed the specified
limit.
Excessive runout is usually caused by worn or damaged bearings. If, after replacing the bearings, the
runout still exceeds the prescribed limit, replace the
wheel rim.
Maximum radial and axial runout: 2 mm (0.078 in)
Speedometer drive
Check that it shows no signs of damage and/or
excessive wear.
Tyre
Check the condition of the tyre (TYRES).
chap. 7
Release 00
2002-09
7-25
Cycle parts
Atlantic 500
REFITTING THE FRONT WHEEL
CAUTION
When refitting the front wheel, take care not to
damage the brake line, the disc and the pads.
Position the wheel between the fork rods.
Insert axle (1) from the right side of the vehicle.
Insert the spacer (2) between the hub and the left fork
rod.
Insert the spacer between the hub and the left fork
rod.
Screw and tighten the wheel pin (1).
2
1
3
NOTE Perform these operations also on the vehicle
r.h. side.
Carefully refit the brake caliper to brake disc (4).
Tighten the two screws (5).
While pulling the front brake lever, repeatedly stroke
the fork by pressing down on the handlebar.
This will allow the fork rods (1) to settle appropriately .
Tighten axle clamp screw (3).
5
CAUTION
4
After refitting the parts, repeatedly pull the front
brake lever and check the operation of the braking
system
5
Check the wheel centering and balancing, see
(WHEELS/TYRES).
7-26
Release 00
2002-09
chap. 7
Cycle parts
Atlantic 500
REAR WHEEL
5
4
1
3
2
7
KEY
1)
2)
3)
4)
5)
Wheel assembly
Spacer
Oil seal
Brake caliper and silencer supporting plate
Nut
chap. 7
Release 00
2002-09
7-27
Cycle parts
Atlantic 500
REMOVING THE REAR WHEEL
Read through the paragraph (PRECAUTIONS AND
GENERAL INFORMATION).
7
Put the vehicle on the central stand.
5
WARNING
Allow the engine and the exhaust terminal to cool
down completely.
3
6
Remove the exhaust terminal, see (REMOVING THE
EXHAUST TERMINAL).
Unloose and remove screw (5) fixing the pipe guide
clamp.
Unloose and remove the two screws (6) fixing the rear
brake caliper (7).
Release the rear brake caliper (7) from the support
(3).
Unscrew and remove pin (8) fixing the suspension
(11).
11
9
8
10
Keep nut (9) and washer (10).
Release the right suspension (11) of support (3).
Unscrew and remove the wheel pin nut (12) using a
pneumatic gun.
Unloose and remove the two screws (13) fixing the
support (3) to the engine. Keep the washers.
Remove support (3) by pulling it outwards.
Remove wheel (14) by pulling it outwards, including
the rear brake disc.
3
13
12
14
7-28
Release 00
2002-09
chap. 7
Cycle parts
Atlantic 500
REMOVING THE EXHAUST TERMINAL
Read through the paragraph (PRECAUTIONS AND
GENERAL INFORMATION).
Put the vehicle on the central stand.
WARNING
Allow the engine and the exhaust terminal to cool
down completely.
1
Unloose clamp (1) by unscrewing the nut fixing the
exhaust terminal to the manifold.
Unscrew and remove the three bolts (2) fixing the
terminal to support (3), keep the relevant nuts.
Remove the exhaust terminal (4).
3
2
4
2
chap. 7
Release 00
2002-09
7
7-29
Cycle parts
Atlantic 500
CHECK
CAUTION
Check the condition of all components and in
particular of those listed below.
1
Bearings
Manually rotate inner race (1), making sure it turns
smoothly without any sticking and/or noise.
Check that there is no axial play.
Replace any bearings showing the above defects.
CAUTION
Lubricate the balls (or rollers) on the side of each
bearing, see (TABLE OF LUBRICANTS).
Lubrication is not necessary if the bearing is of
the self-lubricating type.
Axle
Refer to the ENGINE WORKSHOP MANUAL no.1063
, no.1064 , no.1065 , no.1066 , no.1067
and no.1068 .
Wheel rim
Using a dial gauge, check that the radial and axial
runout of the wheel rim does not exceed the specified
limit.
Excessive runout is usually caused by worn or damaged bearings. If, after replacing the bearings, the
runout still exceeds the prescribed limit, replace the
wheel rim.
Maximum radial and axial runout: 2 mm (0.078 in)
Tyre
Check the condition of the tyre (TYRES).
FRONT BRAKE
For general information, refer to the paragraph
(BRAKES FLUID).
For more information on:
Braking system parts, see (BRAKING SYSTEM).
Pads wear checking, see (CHECKING PADS WEAR).
Braking system bleeding, see (BRAKING SYSTEM
BLEEDING).
7-30
Release 00
2002-09
chap. 7
Cycle parts
Atlantic 500
1
8
2
4
5
3
6
8
7
5
3
7
9
9
KEY
1)
2)
3)
4)
5)
6)
7)
8)
9)
Brake control lever
Brake fluid pump/tank
Brake fluid pipe
Braking retarder
Brake caliper breather valve
Pipe fitting screw
Brake caliper
Brake pads
Brake disc
chap. 7
Release 00
2002-09
7-31
7
Cycle parts
Atlantic 500
REPLACING THE BRAKE PADS
Read through the paragraph (PRECAUTIONS AND
GENERAL INFORMATION).
4
Put the vehicle on the central stand.
NOTE Perform the following operations on both
1
sides.
Unloose and remove screw (1).
Unloose and remove the two screws (2) and release
the brake caliper (3).
Hold the brake caliper in one hand and remove plate
(4).
Remove the two pins (5).
Remove the two pads.
2
CAUTION
Do not pull the brake lever after removing the
brake pads as the caliper pistons may come out of
their seats and cause a leakage of brake fluid.
3
CAUTION
5
Always replace both pads and make sure to
properly position them inside the caliper.
2
Fit two new pads.
Insert the two pins (5).
Correctly position plate (4).
Screw on screw (1), without tightening it.
Correctly position the brake calipers.
Screw and tighten the two screws (2).
Screw and tighten screw (1).
7-32
Release 00
2002-09
chap. 7
Cycle parts
Atlantic 500
CHECKING THE BRAKE DISC
CAUTION
The following operations must be performed when
the brake disc is installed on the wheel.
Visually check the surface of the brake disc. If it
shows any signs of scoring or damage, replace the
disc (REMOVING THE BRAKE DISC).
Check the wear of the brake disc by measuring its
minimum thickness with a micrometer at several
points.
If the minimum thickness of the disc, even at one
point, is less than the prescribed limit, replace the
disc.
Minimum thickness of the brake disc: 3.5 mm (0.137
in)
With a dial gauge, check that the disc oscillation does
not exceed the allowed tolerance. Replace if necessary.
Brake disc oscillation tolerance: 0.1 mm (0.004 in)
7
REMOVING THE BRAKE DISC
Read through the paragraph (PRECAUTIONS AND
GENERAL INFORMATION).
Take down the front wheel (REMOVING THE FRONT
WHEEL).
Remove the five brake disc screws (7).
NOTE Turn in all screws manually, and then tighten
them diagonally in the following order: A-B-C-D-E.
Check the disc direction of rotation.
CAUTION
When refitting, apply LOCTITE ® 270 over the
threads of the brake disc screws.
Remove the brake disc.
REAR BRAKE
For general information, refer to the paragraph
(BRAKES FLUID).
For more information on:
Braking system parts, see (BRAKING SYSTEM).
Pads wear checking, see (CHECKING PADS WEAR).
Braking system bleeding, see (BRAKING SYSTEM
BLEEDING).
chap. 7
Release 00
2002-09
7-33
Cycle parts
Atlantic 500
11
7
2
8
10
5
1
9
10
4
3
6
12
KEY
1) Brake control lever
2) Brake fluid pump/tank
3) Brake fluid pipe
4) Valve
5) Pipe fitting screw
6) Brake caliper
7) Pad pin
8) Stop ring
9) Brake pads
10) Antivibration plates
11) Pad spring
12) Brake disc
7-34
Release 00
2002-09
chap. 7
Cycle parts
Atlantic 500
REPLACING THE BRAKE PADS
Read through the paragraph (PRECAUTIONS AND
GENERAL INFORMATION).
1
Remove the rear brake caliper, see (REMOVING THE
REAR BRAKE CALIPER).
Remove stop ring (1).
Remove pin (2).
Remove spring (3).
CAUTION
The vibration-damping plates are removed together with the pads.
Remove the pads (4) (complete with the vibrationdamping plates (5)) by withdrawing them one by one.
4
3
5
CAUTION
Do not pull the brake lever after removing the
brake pads as the caliper piston may come out of
its seat and cause a leakage of brake fluid.
Replace the pads (4).
Replace the vibration-damping plates (5) if they show
signs of wear.
2
7
WARNING
Always replace both pads and make sure to
properly position them inside the caliper.
Fit two new pads and vibration-damping plates paying
attention to the assembly direction (direction of rotation of the wheel).
Correctly install the spring (3), see Turn Indicator.
Fit the pin (2).
Fit the stop ring (1).
Check the brake fluid level, see (CHECKING THE
BRAKE FLUID LEVEL).
chap. 7
Release 00
2002-09
7-35
Cycle parts
Atlantic 500
CHECKING THE BRAKE DISC
CAUTION
The following operations must be performed when
the brake disc is installed on the wheel.
Visually check the surface of the brake disc. If it
shows any signs of scoring or damage, replace the
disc (REMOVING THE BRAKE DISC).
Check the wear of the brake disc by measuring its
minimum thickness with a micrometer at several
points.
If the minimum thickness of the disc, even at one
point, is less than the prescribed limit, replace the
disc.
Minimum thickness of the brake disc: 3.5 mm (0.137
in)
With a dial gauge, check that the disc oscillation does
not exceed the allowed tolerance. Replace if necessary.
Brake disc oscillation tolerance: 0.1 mm (0.004 in)
REMOVING THE BRAKE DISC
Read through the paragraph (PRECAUTIONS AND
GENERAL INFORMATION).
Take down the front wheel (REMOVING THE FRONT
WHEEL).
Remove the five brake disc screws (7).
CAUTION
When refitting, apply LOCTITE ® 270 over the
threads of the brake disc screws.
Remove the brake disc.
7-36
Release 00
2002-09
chap. 7
Cycle parts
Atlantic 500
STEERING
2
For information on how to check and adjust the
steering, refer to the paragraph (CHECKING AND
ADJUSTING THE STEERING).
4
1
Disassembly
Read through the paragraph (PRECAUTIONS AND
GENERAL INFORMATION).
Remove the handlebar cover, see (REMOVING THE
UPPER HANDLEBAR COVER) and (REMOVING
THE LOWER HANDLEBAR COVER).
Put the vehicle onto an elevator, leaving the front
wheel out, and lower central stand.
5
3
CAUTION
Place a suitable support under the vehicle so as to
prevent it from falling.
The vehicle should rest on the frame and not, on
any account, on the fuel tank.
Ensure that the vehicle is stable.
Unloose and remove screw (1).
Keep nut (2) and the washers.
Unloose and remove screw (3).
Keep nut (4) and the washers.
Remove the front mudguard, see (REMOVING THE
FRONT MUDGUARD).
7
8
CAUTION
Arrange for a suitable support to hold the handlebar that remains connected to the vehicle by
means of the electrical cables and the brake pipes.
Proceed with care. Do not force the electrical
cables.
6
Completely pull upwards the handlebar (5) (complete
with switches).
Unloose and remove the two screws (6).
Release the plate (7) of the steering trapezoid (8) of
the steering suspension.
7
Unloose and remove screw (9) and release the
odometer sensor (10).
10
9
chap. 7
Release 00
2002-09
7-37
Cycle parts
Atlantic 500
NOTE Perform the following operation also on the
11
vehicle l.h.side.
Unloose and remove the two screws (11).
Release the brake caliper (12) from the fork.
12
CAUTION
Do not pull the front brake lever after removing
the brake caliper as the caliper piston may come
out of its seat and cause a leakage of brake fluid.
11
Unloose and remove the two screws (13)
Remove the brake oil pipes stop plate (14).
Release the pipes and the brake caliper from the fork.
13
14
15
Remove counternut (15).
16
CAUTION
17
Support the fork to prevent it from falling.
20
19
21
NOTE When removing the fork, pay attention to the
balls coming out of the lower bearing.
23
Remove adjusting nut (16).
Remove the plastic gasket (17).
Remove the fork (18) from the steering tube (19).
Remove revolving ring (20) and upper bearing balls
(21).
Remove lower bearing balls (22).
Remove the grease from all bearing components,
fixed rings (23) and (24) included.
Remove the dust cover gasket (25).
Check the components for any signs of wear and
replace as necessary.
25
22
NOTE For the grease type to be used with the
24
bearings, refer to the (LUBRICANT CHART).
Grease and proceed with the reassembly.
18
7-38
Release 00
2002-09
chap. 7
Cycle parts
Atlantic 500
CHECKING THE BEARINGS
CAUTION
Check the condition of all components.
Check that the areas that come into contact with balls
(1) on both revolving ring (2) and fixed ring (3) are not
damaged or worn out. If they are, replace the bearing
assembly.
CAUTION
Grease the two rings (2) and (3) in the areas where
they are in contact with the balls (see LUBRICANT
CHART).
Reassembly
To reassemble, follow the disassembling procedure in
reverse order, taking care to interpose the steps given
below.
CAUTION
Ensure that the pipes and the cables are not
twisted
NOTE The hole for the fixing to the handlebar clamp
must be aligned with the slot on the fork pin.
7
CAUTION
To avoid damaging the steering bearings, take
care not to screw adjusting nut (4) tight.
Screw in adjusting nut (4) until the play of the bearings
is eliminated.
Check the play by stroking the fork in the direction of
motion and checking that the steering can rotate
smoothly and freely.
Lock adjusting nut (4) in position and tighten
counternut (5) with a spanner.
Repeat the second operation.
chap. 7
Release 00
5
4
2002-09
7-39
Cycle parts
Atlantic 500
1
21
2
6
4
3
4
7
6
13
3
11
14
7
15
2
12
5
16
17
8
11
13
24
14
22
15
24
9
16
17
23
19
18
10
20
19
20
KEY
13) Dust cover gasket
14) Lock spring ring
15) Seal gasket
16) Cup
17) Bush
18) Left wheel carrier
19) Seal washer
20) Lower screw
21) Right rod
22) Right wheel carrier
23) Locking screw
24) Bush
1) Fork base
2) Fork clamp screws
3) Spring stop ring
4) Rubber cap
5) Seal cap
6) Brake pipe cable lead
7) “GACO” ring OR type
8) Spring
9) Pumping element
10) Return spring
11) Bottom bumper
12) Left rod
7-40
Release 00
2002-09
chap. 7
Cycle parts
Atlantic 500
CHECKING THE OIL LEVEL
If “ bottom strokes” are noticed in the fork, check the
oil level in the rods.
Remove the front shield, see (REMOVING THE
INNER SHIELD).
2
1
NOTE To facilitate the removal of the two seal caps
(3), it is necessary to remove them both at the same
time.
Remove the spring stop ring (1).
Remove the plastic cap (2).
Slowly pump the fork until the two seal caps (3)
complete with O rings (4) have come out.
2
NOTE Check the O rings conditions. Replace if
necessary.
1
NOTE Check the spring position (5) (the turns with a
smaller diameter and closer to each other must be
facing upwards).
3
4
CAUTION
The spring is immersed in oil.
Avoid dripping the oil when removing the spring.
5
7
85 mm (3.34 in)
Pull out the spring (5).
Move the fork to its full bump position, insert a gauged
rod (meter) in one of the two rods and check that
there is a distance of 85 mm (3.34 in) between the rod
upper edge and the oil level.
Top up the fork oil if necessary. See (TABLE OF
LUBRICANTS).
Repeat these two operations also for the second rod.
REMOVING THE FORK ASSEMBLY
To remove the fork assembly (in case it is to be replaced), follow the instructions described in paragraph
(DISASSEMBLY).
chap. 7
Release 00
2002-09
7-41
Cycle parts
Atlantic 500
REMOVING THE ROD-WHEEL CARRIER ASSEMBLY (with installed fork)
Put the vehicle on the stand.
CAUTION
Place a suitable stand under the vehicle to prevent
it from falling.
Remove the front mudguard, see (REMOVING THE
FRONT MUDGUARD).
Remove the front wheel, see (REMOVING THE
FRONT WHEEL).
Remove the front shield, see (REMOVING THE INNER
SHIELD).
NOTE Perform the following operation also on the
vehicle left side.
Unloose and remove the two screws (1).
Release the brake caliper (2) from the fork.
1
2
6
CAUTION
Do not pull the front brake lever after removing the
brake caliper as the caliper piston may come out of
its seat and cause a leakage of brake fluid.
5
1
Unloose and remove the two screws (3).
Remove the brake oil pipes stop plate (4) and the lock
(6).
Release the pipes and the brake caliper from the fork.
Unloose and remove screw (5).
Remove the odometer sensor (6) from the fork rod (7).
Completely remove, by lowering it, the fork rod complete with the wheel carrier.
Repeat the last three operations also for the second
rod.
6
3
7
4
7-42
Release 00
2002-09
chap. 7
Cycle parts
Atlantic 500
WHEEL CARRIER ROD DISASSEMBLY
CAUTION
Check the oil quantity.
If less than 225 cm3 (13.72 cu.in), top up or renew.
Read through the paragraph (PRECAUTIONS AND
GENERAL INFORMATION).
Unloose and remove screw (6) (wheel carrier bottom)
and keep the copper washer (7).
Remove the rod (8) complete with pumping element
(9).
Turn the wheel carrier (10) to take out the bottom
bumper (11) and the counter spring (12).
Remove the dust cover gasket (13).
Remove the lock spring ring (snap ring) (14).
To disassemble the rubber cap (1), lock spring ring
(snap ring) (2), seal cap (3) complete with O ring (4),
and spring (5), perform the (CHECKING THE OIL
LEVEL) operations on the wheel carrier rod that is to
be disassembled, leaving out the last two oil check
operations.
CAUTION
Pay attention to possible oil leakages as the rodwheel carrier assembly is full with oil.
Do not overturn or incline the unit excessively
when removing it.
CAUTION
To reassemble, make sure the sharp edge of the
lock spring ring (snap ring) (14) is in the same
position as shown in the figure.
Remove the rod-wheel carrier assembly, see (REMOVING THE ROD-WHEEL CARRIER ASSEMBLY) (with
installed fork).
Prepare a container with capacity of at least 200 cm3
(12.2 cu.in).
Let the rod retract completely in the wheel carrier, turn
the rod – wheel carrier assembly and drain the oil into
the container.
Remove the seal gasket (15).
Remove the cup (16).
Remove the bush (17).
7
3
16
5
17
8
10
1
2
11
9
13
4
14
15
7
6
12
chap. 7
Release 00
2002-09
7-43
Cycle parts
Atlantic 500
CHECKING THE COMPONENTS
Rod
The sliding surface must show no signs of scoring and/
or damage.
If the rod is damaged, replace it.
With a dial gauge, check that the rod bending is lower
than the limit value.
If necessary, replace the rod.
Bending limit: 0.2 mm (0.007 in).
WARNING
A bent rod must NEVER be straightened as its
structure would become weak, thus compromising
the vehicle safety.
Wheel carrier
Check that it shows no signs of damage and/or flaws.
Replace if necessary.
Spring
Check the spring condition.
Pumping element
Check the pumping element condition.
Replace if it shows signs of damage.
ADJUSTING THE REAR SUSPENSION
The rear suspension consists of a doubleeffect shock
absorber (braking with compressed/extended shock
absorber) fixed to the engine by means of a silentblock.
The standard adjustment, set by the manufacturer, is
suitable for a driver weighing about 70 kg (154.3 lbs).
If your weight and needs are different, adjust the ring
nut (1) with the appropriate spanner provided in the
tool kit, thus setting the ideal travelling conditions (see
table).
Adjust both shock absorbers to the same position.
7-44
Release 00
2002-09
1
chap. 7
Cycle parts
Atlantic 500
ADJUSTMENT OF THE REAR SUSPENSION
SPRING PRELOAD
Adjusting
ring
Rotation
(arrow A)
Rotation
(arrow B)
Function
Spring preload
increase
Spring preload
decrease
Attitude
The vehicle is more
rigid
The vehicle is less
rigid
Recommended Smooth or normal
roads
kind of road
Notes
Drive with passenger
Roads with uneven
surface
Drive without
passenger
REMOVING THE SHOCK ABSORBER
Read through the paragraph (PRECAUTIONS AND
GENERAL INFORMATION).
Put the vehicle on the central stand.
3
2
WARNING
Wait for the engine and the exhaust terminal to
cool down completely.
6
CAUTION
Remove one shock absorber per time.
To maintain the vehicle in the upright position,
always leave one shock absorber assembled to
the vehicle.
7
NOTE Perform the following operations for both
shock absorbers.
Unloose and remove the lower screw (4) and keep nut
(5).
Unloose and remove screw (2) and keep the nut (3).
Remove the shock absorber (6).
6
5
chap. 7
Release 00
2002-09
4
7-45
Cycle parts
7-46
Atlantic 500
Release 00
2002-09
chap. 7
aprilia s.p.a.
via G.Galilei, 1
30033 Noale (VE) Italy
tel. +39 041.5829111
fax +39 041.441054
www.serviceaprilia.com